VW Lupo 3L --> 2L

[Vekke]

Something for reading:
Handbook of Diesel Engines

from page 450- thing conserning diesel engine BSFC. In short things that increse BSFC in a diesel:
- cooled EGR. VAG system poorly designed. (Too much compromises)
- Injection pressure increase. That can be increased in some TDI engines, changing the pump or playing with injection advance.
- Supercharging or turbocharging. So if you already have a turbo you need to increase the boost pressure to get better efficiency. To be able to do that you need the next thing that improves efficiency
- Intercooling. Basic intercoolers efficiency can only be up to 75%. Water/air cooler up to 95% without ice in water tank. Water injection can be over 100% without intake restrictions and pressure losses . So when you install water injection you can give the engine more boost, it will increase power from methanol etc.
https://www.alcohol-injection.com/en...ory/2-articles
in short:
Increase horsepower safely by 10-15%.
Lower air temperatures by 50-200+ degrees.
Decrease cylinder temperatures up to 300 degrees.
Reduce the effects of heat soak in warmer climates.
Allows you to safely run more boost and timing.
Reduces carbon and helps maintain a clean combustion chamber.
Increases octane at user programmable boost levels.

That BSFC list is longer but those are mentioned in that list. You can even optimize your altenators RPM and charging current for best efficiency!

[ausias]

using methanol 116 octane in a diesel engine (15 to 25 octane in common diesel fuel)? almost incompressible water injection in a compression engine? using kerosene as injector cleaning (low octane) i think is enough (diesel mixture with 95 octnae petrol when cold i heard and used withou problem). Hybrid fuel methane and diesel (90% and 10%diesel) I know trucks using it, but methanol injection in a TDI engine this is the firs time.

What injection kit will you use? I looked for 1.9 Tdi kit and I did'nt found. They say MAx power increase is +10 to +15% power increase. Does it mean -9 to -13% fuel consumption all over the BSFC map?

I have a lot of questions. AHahahahah

[euromodder]

Originally Posted by ausias

using methanol 116 octane in a diesel engine ?

but methanol injection in a TDI engine this is the firs time.

Are you guys on the same frequency ?

The water/methanol goes in the air intake, not as a direct fuel replacement.

With diesel+methane , the CNG is als fed into the airstream going into the engine.

[Vekke]

I am not a expert of those systems but I would estimate that it saves fuel all over the rev range when it is injected. Savings can be up to 12%.

That stuff is injected to your intake piping. Best place is right after the turbo so there is more time to cool the intake temps.

[ausias]

I found that methane has higher octane than methanol and can be injected witout problems in the air intake in diesel cycle engines (to get more power, but also burning less petro/biodiesel because of the mixture). So I'm wondering what are diferences between liquid or gas aspiration injection.
One example of bifuel( gnc diesel) aspiration injection i found TDI CNG kit installed - TDIClub Forums

High pressure methane/diesel fuel injection is possible and used (bus, train, truck): Westport

Dear CarMakers: I want my 1.9 HPDI instead of TDI (and if you can replace TDI with Turbo Hidrogen Injection/Intercooled diesel cycle ICE it will be aprreciated).

I'm doing Boost, MAF logs with vag-com and I think that N75 turbo geometry actuator will produce interferences in P&G and fuel savings. My TDI 110 cv 12 years 310.000 km turbo geometry and actuator have better correlation between Especificied and Actual values than my TDI 105cv@138cv 5 years 100.000 km (overboost,underboost and some boost creep) ahahaha
Your car has 250.000 kms and maybe some dirty variable geometry turbo or n75 regulation lag. Did you clean your turbo, intake, EGR, etc.?
But i found a solution to boost in this links (written in spanish, but you will appreciate photos, vag com/vcds logs and part names, etc. and maybe automatic traslation in your languaage could be understood) read all the pages because you will find data logs obtained with months od diference.

Boost valve fitting:
Instalación de Boost Valve en 1.9 TDI 105CV (BKC, BJB, BXE)
Montar Boostvale en TDI

N75 cleaning:
DIAGNOSIS/REPARACION DE LA N75 (GESTION GEOMETRIA DEL TURBO)

N75(electronic sensor regulator boost valve) diagnose and N18 (in maf channel, EGR valve open/close %) using VAg com /VCDS or other obdii tools VAG comaptible.
BRICO:Comprobar y cambiar N75 y N18 - Audisport Iberica
http://www.niovus.com/mecanica/Como%...%20VAG-COM.pdf

I don't know if you n75 valve is in a box with 2 oter valves more like mine (1.9 tdi BXE) if you want and independent one conversion here is a how to:
[Manual] Adaptación N75 independiente en coches con caja de válvulas

user Fran_OC in areavag forums says he obtained fuel savings after good turbo regulation (logs only show fast turbo without lag at low-medium rpms) and other expert m0nch0 says mayba 0.5 L/100km saving.
we know about measrure method importance so I think it's agood think to test if not assessed yet.

I will test in future days but it will be useful if anyone has their own boost maf logs to compare, with and withou boost valve, as fuel consumption with and withou boost valve.

USefulness of engine logging
Usefulness of Engine Logging | Malone Tuning Ltd.
I have Boost Spikes and underboost when full throttle as showed in About Custom Tuning | Malone Tuning Ltd. because my chip tuning at www.vimauto-motorsport.com and maybe n75 or vgt clean needed. I will do my research.

[Vekke]

I had a broken maf sensor. Now its fixed. Will also change fuel temperature sensor and water thermostat just to be sure.

New ECU program revision 1 is installed:

http://www.youtube.com/watch?v=3fkXr...1&feature=plcp

Old turbo could not handle the back pressure after 4000 rpm. Tomorrow will go to pick up 3 new Borg Warner BV35 turbochargers, yes 3. Those should be good to go up to 120 Hp!. I have to thank Turbotekniikka Oy for those new turbos. They gave me also some valuable information on engine tuning and setup which I should try.

Water injection system is installed and intercooler is put back in place.

Today installed some front wheel fairings:
https://fbcdn-sphotos-a.akamaihd.net...85642828_n.jpg

I have reserved a time for some standing mile acceleration on 7.7.2012. Target is to beat best lupo so far which means 181 km/h end speed.

[lowglider]

That`s awesome. 120hp in what, around 700kg weight? Hope you get the record

[Vekke]

About 830 kg (driver included) and 120 hp is long term target on first step 100 hp.

[Fionn]

Hi Vekke, the turbo chargers sound great, however are you not concerned about your gearbox?
I have a 1.7SDI Seat Arosa and gearbox (085) failure is very very common in them.
Mine failed about 5000km after I bought it and it took me a while to locate a 2nd hand one which I then got refurbished before installing it back into my car.
This is with just 44kW though!
I was told by the gearbox company I used that the box is just the petrol box with different ratios and that it is not up to the job diesel engines. It is one of only 2 gearboxes in production that they do not refurbish - I got no guarantee with mine.
When mine fails again I'm considering installing a larger gearbox from a Golf or similar however this will involve custom mounts and some butchering of the chassis to make it fit!

Fionn.

[ecomodded]

I have been contemplating front wheel fairings for my Beetle but never came up with a idea i like as much as your front w fairings.
Could you tell me how you made them?
If i copy them, you will get full credit for the design or inspiration
If the design is not yours.
The splitter designed into it is spectacular.

Quote:
Today installed some front wheel fairings:
https://fbcdn-sphotos-a.akamaihd.net...85642828_n.jpg