Date: Thu, 18 Mar 2004 19:07:21 -0800
Reply-To: David Marshall <vanagon@VOLKSWAGEN.ORG>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: David Marshall <vanagon@VOLKSWAGEN.ORG>
Subject: 1.9TD with EGT / Oil Temp / Boost Test Drive Results
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Just got back from 'rallying' the heck out of a 1985 2WD Westfalia camper
with a 1997 Golf AAZ Turbo Diesel (1.9L) engine that installed for a
customer.
1.9L Motor stats:
Thermostat: 80C (176F)
Turbo: Stock K03-006
Boost Level: Set to max out at 0.8BAR (12PSI)
Timing: 0.80mm (stock).
Fueling levels: Stock.
Intake system: Custom 2.5" aluminium pipe between turbo and factory Vanagon
air box (very quiet!!).
Air Box Filter: Paper.
Muffler: 2.5" with a single free flow muffler.
Mounting Angle: 15 Degree with Fast Forward mounting kit.
Van Stats: Stock 1985 Westfalia - empty
Transmission: 4 Speed with stock gearing
Tires: 195/75R14 - stock diameter
Extras: VDO Exhaust Temp Gauge - probe before turbo
VDO Oil Temp / Oil Pressure / Boost Gauge
Environment: 600m/2000ft above sea level, 10C/50F, overcast, 99.2kPa/29.3",
Humidity 29%
The drive I like to do is a 15km (9 mile) section of highway 97 just north
of Quesnel. It starts in Quesnel, which is in a valley on the Fraser River
and goes up a series of long steep uphills with small valleys along the way.
Gain in altitude is about 300m/1000ft.
The test drive consisted of going down town Quesnel to fill up on Diesel and
to get the fluids up to operating temp. At the beginning of the first big
hill the oil temp was 80C (175F), exhaust was about 175C (350F) - 200C
(400F), water gauge was just above the white 'cool' section. At the end of
this section driving FAST (max speed was 135km/h (85mph) average about
110km/h (70mph) the oil temp was just over 100C (212F), water temp was 1/2
between the LED and cold, the maximum EGT I saw was 600C (1100F) for about 2
to 3 seconds, during full boost 0.7 to 0.8 BAR (10 to 12PSI) durations of
more than 10 seconds the average EGT was between 425C (800F) and 500C
(900F), as soon as you take the foot off the accelerator, the temps would
immediately go down, driving on the flats at 100km/h (62 mph) was resulting
in 230 (450F) to 320C (600F) EGTs. Outside temp was 10C (50F) - I expect
these numbers to change a bit on a scorching hot day.
So overall, I was VERY impressed with the performance of this motor in the
Westfalia. This van with a 1.9TD certainly outperforms a 2.1L wasserboxer,
I never took the van out of 4th gear and never dropped below 95km/h (60 mph)
(only occurred once) on any of the hills. I think this is pretty darn
decent for a 75hp Diesel motor. In a 2.1L wasserboxer (even my 112hp
TriStar) I had to attack the 1st hill in 3rd gear and maybe achieve 95km/h -
I did the same hill in 4th with the Diesel and it never dropped below
95km/h! I think having the torque below 3000 RPM is what really counts on
our Vanagons. The 1.9TD has the same torque as the 2.1wbx only 1000 RPM
lower.
Just a note on Exhaust Temperature gauges aka Pyrometers, well, at least VDO
gauges anyhow. This business of using the correct K sender style wire for
the entire length of the run is a bunch of bull! I went out an bought a
spool of the correct "yellow wire, red wire" cable so that I can have the
same stuff from the probe to the gauge. Just for the heck of it I ran some
good speaker wire from the front to the back too and switched the wires back
and forth - no difference in readings - at least not in the 400 to 600F
range anyhow. My engineer friend at the pulp mill told me that the correct
lead wire is only necessary if you have a self powering gauge or need
resolution better than 10 degrees. The VDO gauge requires 12V to operate.
The Pyrometer measures the difference of voltage at the end of the K sender
wire and good quality copper wire will have so little resistance that it
won't make a difference that you can see on a powered analog gauge like the
VDO gauge where each gradient is 200F . He was right!
David Marshall
Fast Forward Automotive Inc.
4356 Quesnel-Hixon Road
Quesnel BC Canada V2J 6Z3
http://www.fastforward.ca mailto:sales@fastforward.ca
Phone: (250) 992 7775 FAX: (250) 992 1160
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