Date: Tue, 31 Aug 2004 17:29:10 -0700
Reply-To: Robert Lilley <RClilleyjr@COX.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Robert Lilley <RClilleyjr@COX.NET>
Subject: Re: 28.8 MPG
In-Reply-To: <CGEHKAABPGGIIBCALNJJAEIICIAA.shiva@edcnet.org>
Content-Type: text/plain; charset="us-ascii"
It is the black box in the center of the engine where the runners from the
cylinder head go into.
I would say it is due to the small changes I made to the stock engine
configuration to make the engine run more efficiently.
-Counterweighted crank to reduce losses to harmonics, reduces engine
vibrations
-Full balancing of all rotating parts
-Mild porting of heads to remove casting imperfections and improve flow
-ECU chip to make the engine run better
-An adjustable fuel pressure regulator to better match fuel pressure to
intake changes
-Adding ceramic coatings to all parts that touch exhaust heat to reduce heat
radiating into the engine and keep exhaust flow higher to create a better
vacuum on incoming intake charge.
-Changing muffler to eliminate restrictive stock muffler allowing for less
HP lost to forcing exhaust out
-Match porting the intake and exhaust systems end to end. This eliminates
HP loss due to flow restrictions
-Changing to K&N air filter reduces intake flow restrictions and allows for
more air to fill intake cylinder per intake stroke creating more power
availability, enables cylinder to make better use of intake stroke to be
able to pull more air into cylinder.
-Quad tip platinum stark plugs, change flame kernel, un-shields spark to
provide more spark exposure to fuel air mixture promotes more complete burn.
-Blueprint and match port oil pump to improve oil volume, reduce cavitations
and maintain better oil pressure through rpm range
-Increase duration on stock cam and increase lift on exhaust to match
intake, moves power band up RPM scale, increase upper rpm engine breathing
-Roller tip lightweight 1.3 ratio rockers, increase in ratio helps low end
power by opening valves sooner and accelerates lift to allow for increase in
airflow sooner that stock cam. Reduces the weight the stock spring needs to
control and eliminates the need to go to heavier springs when using ratio
rockers and therefore eliminating the power loss associated with heavier
springs and loss of mileage.
-3 angle valve job to increase flow and efficiency in the engine ability to
breath.
-Ceramic coating of the head gasket sealing surface to eliminate the
corrosion problem and the heat blocking effect will increase usable service
life of the rubber gaskets
Are some of the changes made to the stock engine. I would make some
additional changes, stainless steel valves [lighter (less weight for spring
to control) and smaller stem design (allows for increased flow)] and bigger
pistons (95mm to 98 mm) and increase stroke from 76 mm to 80 mm to 84 mm and
better rods. I really want to find a way to make the injectors sequential
fired...
I basically wanted to take a stock engine and improve upon it, what VW
should have done, and make it better and more reliable.
There are other things that I have done.
You can go to my web page I am developing
http://88vanagon.wasserboxerpower.com/88vanagon/index.htm
And see some of what I have done. It has some big audio files so be patient
while it loads.
Some people want to toss the WBX and swap it out while other are OK with it.
I am OK with it and want to make improvements to make it more reliable and
make a bit more power.
-----Original Message-----
From: Shiva Polefka [mailto:shiva@edcnet.org]
Sent: Tuesday, August 31, 2004 4:47 PM
To: Robert Lilley
Subject: RE: 28.8 MPG
wow, really impressive results. A couple novice questions, if you dont mind
my asking: first, is an air plenum an air filter? second, is 28.8 largely
acheivable due to your engine mods? Or just tight maintenance? I would
really dig getting my efficiency up. TIA/ sp.
-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@GERRY.VANAGON.COM]On Behalf
Of Robert Lilley
Sent: Tuesday, August 31, 2004 3:48 PM
To: vanagon@GERRY.VANAGON.COM
Subject: 28.8 MPG
Well, I finally got around to replacing my air plenum, throttle body, air
runner gaskets, FI seals, setting back timing to stock setting and fixing
fuel leak in one line (previously unknown), ADDED 4 missing clamps for the
idle speed control valve circuit; Two on the rubber tube and 2 on the
grommet on the center plenum and ISCV.
I took the throttle body apart cleaned, replaced the seals and Set the gap
on the switch. I put on a used newly painted center plenum, replaced the
gaskets under the air runners added new seals and added clamps that were
missing. While looking at ETKA, I noticed that there were clamps on the
ISCV circuit. Mine had none, so I ordered some.
I went for a 55 mile drive. About 10 miles were in city traffic the rest was
on highway going ~65. I filled up just prior to taking the trip and it
lasted @1 hour in 100+ heat in Mesa AZ. I filled up immediately after
stopping the trip. Starting on a full tank and then filling back up it took
1.9 US gal. While this is no means scientific, many more miles need to be
run, it is just nice to finally get the mileage back up.
I did not use AC it is soon to be fixed, I did not rev the engine high, just
normal take offs. I used barely any pedal to keep going 65+. The Digifant
FI is not a "racing" FI system but a "cruising" one.
Next project is the A/C along with cooling system flushing and some minor
parts replacing.
This is with a modified WBX engine.Cam, crank, ECU chip, ratio rockers,
exhaust, intake, etc.
PS When I first put my modified engine in, I was having a noticeable whistle
when I first opened the throttle. I replaced gaskets and rebuilt the
throttle body, chased a lot of things but the whistle was still there.
Finally after changing the throttle body and center air plenum it has
virtually disappeared. Do not know if it was the throttle body or the
center plenum. I would suspect the center plenum because there is nothing
physically wrong with the throttle body I can detect. The shaft is tight,
seals are new and soft, no defects that I can find.
PSS If you do not believe me, come and let's go for a ride.
