Project double my VeeDub's mpg

[dremd]

Unfortunately my Golf TDI met an untimely demise last year due to a hit and run.

Many of you guys know my affinity for vehicle features and how much troubble it is to get a TDI VW with them, so this time I've decided to buy a Loaded (GLS Premium) Jetta wagon and swap a TDI 6 speed manual drive train in to it.

The wagon is clean -> super clean 03 Reflex silver with power memory light gray leather interior, climatronic, Electronic Stability Program, auto dimming miriors, automatic wipers, monsoon stereo, steering wheel controls, larger brakes (I know, more rolling mass, but I like them when towing), and all of the regular goodies that you get on a VW. Dealer maintained with a scary stack of receipts that I would never have paid.
$6500 in Cedar Rapids.

I Flew up on American Airlines (watched pilot cruise at 550 mph to arrive 30 minutes early, only to sit on ground waiting for a gate and realized why they go bankrupt so frequently.) the owner was super concerned I would freak over some scratches in the rocker panel from a wheel chair bound husband that I later covered up with some rino liner. I then set off for home 1200 miles away on a 1 1/2 day time schedule, so I was stuck driving at (or +1). Mileage was (and still is) terrible 24-25 mpg. Made it home with no issues.

I Found a 250,000 mile ALH at what I considered to be a great deal, and have been tearing it apart. Cylinder walls still show cross hatching, cam still shows cross machining marks except for 1/8" at peak of ramp up (I'm thinking about replacing it. The main bearings were well within new spec, but I replaced them because they had a spot where they had worn away the coating, all new stretch bolts, new oil pump to replace one sheared off in accident, new oil pan with oil temp + level sensor, exaust wrap on turbo manifold, a new oil bypass filter setup, and a few other bits.

Also got a DRW 6 speed and associated bits.

I'm pretty busy in spring, so the swap will have to wait until early summer, hopefully soon because this mileage is killing me.

[NachtRitter]

Should be pretty easy to double the gasser FE with the TDI swap... Look forward to the results. Any TDI power improvements planned (since some power improvements seem to benefit FE as well)?

[MetroMPG]

That's the first I've read about the demise of your Golf - that's a bummer!

Subscribed and looking forward to the new project though.

[dremd]

Oh man, apparently my forum notifications are broken.

Swap shouldn't be terrible, I've got 03 harness, ecu, vsv's. I'll keep this updated for sure.

Power Mods: Malone tune, PD 150 turbo inlet pipe, PD150 intake manifold Bosio injector nozzles.

Other motor mods: bypass oil filter, pre-plumbed for pre-post lube oil pump (would make me ok with turning motor off more frequently) larger oil-water heat exchanger for faster oil warm up (and more max oil cooling for towing), lots of insulation on valve cover, oil pan, some parts of block, and on the turbo manifold, oil level sensor (factory in many countries), FIS control for lots of data available on factory (imported) cluster, EGT sensor pre-turbo, new timing belt and other bits, new bearings, new thrust washers (only part that shows wear), all new factory stretch bolts, oh and a 6 speed transmission.

I kept the accident a secret because I spent 5 months arguing with insurance which failed miserably at repairing it (let's just say the right rear wheel became detached from the car AFTER it was repaired), and then undervalued it so dramatically that I couldn't have purchased a base model gasoline car in running condition. In hind sight, I made minimum wage dealing with insurance, gave my car away for free, and wished I had just had liability and just delt with it myself. All that despite the fact that I had an accurate description of the truck that hit me, photographs, a license plate #, parts of my car dangling from his truck, and this was the third time he had been reported as committing a hit and run so far last year.

If you get in a wreck where I live and it is your fault I would highly recommend leaving the scene, worst case you admit it and will have to pay a $200 fine in addition to regular accident stuff. If you don't admit, you need video, and 3 un-related witnesses to prosecute the hit and run offender, and then just $200.

[dremd]

Oh, I now have a plasmacam (CNC plasma cutter) so hopefully once I have a running TDI I can make some re-produce able aero bits (mine will probably be all underside).
But if any one wants some plasmacam parts, hit me up.


As another note: I made a list of Golf vs jetta differences here TDIClub Forums - View Single Post - differences between golf and jetta?

I'd say biggest differance is how people see it, despite being nearly identical, to most people it apparently looks way way newer and larger.

[dremd]

Did quite a few not so Eco-mods recently (some help, none really hurt).

1) Installed orange TPMS (highly recommended, not just for price, just for TPMS as well).
2) fixed several leaks in the tires that the car came with (6 total nails/ wires).
3) installed R-line dead pedal which believe it or not, allows quicker cornering for me so I don't slide around in the cushy seat.
4) installed early MKIV style sunroof switch that allows full open of sunroof with a single turn vs turn and hold (I know it sounds super lazy, but I probably use the A/C a tad less.
5) started keeping a Fuelly for the car.
6) flushed the brakes several times, I don't think they were dragging, but they now feel normal vs mush that they felt before. As a side note, I'm always amazed how quick normal people kill brakes, this car had a full set at 50k, my last car had 250k on fronts, and the rears made it to 200k.
7) started thinking about trailler hitch, this guys is almost perfect, but I'll run mine down another inch so the top matches with the bottom of the bumper and blends with the rear valence. Custom 2" trailer hitch installed - Pics - TDIClub Forums as another side note, mine is the same color/ gen wagon as his.
8) added bluetooth/ iPod integration to factory stereo. Still need to add my Sirius radio.
9) imported another FIS cluster from Deebeaux - Euro VW/VAG/TDI Parts & Tool Rentals . Dave is the man for all things cluster related! Highly recommended, you can also find him on TDIclub and occasionally the vortex.
10) ScanGauge II mounted
11) picked up a BlackVue DR 400G BlackVUE DR400G HD - In-car Full HD Camcorder - GPS Version - Taxi Security Camera - Vehicle Security Camera very impressive, gets license plates all weather with ease, faces are sketchy at best. Also records vehicles speed and location (from GPS) and multi axis g-force from an accelerator. Draws a tad over 1 amp (12 volts) in driving mode, and about 3/4 amp in parked mode (no GPS/ acceleramator). Technically this wouldn't have saved me, but I would have had a solid civil case against the guy with video.
12) probably a dozen more tiny things that I can't remember while sick with bronchitis.

[MetroMPG]

That's a complete bummer about the insurance hassle (understatement). But thanks for the post-crash advice, for next time I find myself debating whether to run after the hit!

Are you at least enjoying the re-modding process, or is it all just a big pain?

[dremd]

Metro: no idea on the laws in Kanukastan, so be careful.

Re-modding is nice, because I get to pick EVERYTHING out with the benifit of hindsight, however right now I'm coming up on a timing belt interval on the current motor, and I'm busy for the next month and I'm in need of a car. Err, the frustrations. When the motor is swapped, I think it will be well well worth it.


Another note, any idea on the data source of CDA's at Vehicle Coefficient of Drag List - EcoModder ?
I swapped to the wagon partially due to the marginally smaller CDA of jetta wagon6.47 vs the golfs 6.89. That said, the origional EPA was 1mpg higher on the wagon 50 vs the 49 highway of the golf/ jetta sedans, despite the 200 lb curb weight penalty of the wagon.

[MetroMPG]

Sorry... can't comment on the CDA values. I like it when people link to sources. The wiki list came from multiple users and sources, I'm sure.

That said, I'd be a bit skeptical ... I remember doubting the wagon vs. sedan mpg figures before. I think I even made a thread about it. All else (drivetrain) being equal, it doesn't make sense that the wagon should have a better rating.

[NachtRitter]

Originally Posted by dremd

...
11) picked up a BlackVue DR 400G BlackVUE DR400G HD - In-car Full HD Camcorder - GPS Version - Taxi Security Camera - Vehicle Security Camera very impressive, gets license plates all weather with ease, faces are sketchy at best. Also records vehicles speed and location (from GPS) and multi axis g-force from an accelerator. Draws a tad over 1 amp (12 volts) in driving mode, and about 3/4 amp in parked mode (no GPS/ acceleramator). Technically this wouldn't have saved me, but I would have had a solid civil case against the guy with video.
...

Will be interested to hear how this works for you... I see a lot of good and a lot of bad reviews.