Is this 1.6td setup right?

[punkvideo81]

I'm wondering if I can drive faster on the highway while keeping my egt's reasonable
Here's what I have in my 81 rabbit p/u:

1.6td, intercooled, giles pump, 3" dp & exhaust, k14 turbo, ACN 5 speed trans
According to my boost gauge I'm pushing just around 18-20psi when I get on it, and egt's are often in the 800+ range when on highway@ 70+ mph/3000+ rpm's. Can I roll @ 800+ degree egt temps safely for many highway miles? Is there anything I can I do to lower my egt's while at highway speeds? It's fine around town, delivering good power and lower egt's. Will a larger intercooler help? It currently has the small callaway gti ic.

[8v-of-fury]

800C? or 800F? I assume Fahrenheit as you live in NY.

I'm pretty sure 800 is sustainable.. as it takes at least 400f to ignite diesel alone..

I ASSUME 800F is ok to sustain..

[mystery3]

Get a more efficient turbo or turn the boost down to 10-12psi where the k14 will be nearer its happy zone.

[carrizog60]

a bigger turbo will give less backpressure,that will also help.
maybe a tdi gearbox swap,but that is more money

[jb86]

Keep it under 1100 or si
The highest I let mine go is that
As long as you keep it under the Mac temp you can sustain all day long
800 is plenty safe
Then a bit higher while climbing a hill or accelerating
My duramax pick up runs 800 on the highway
When climbing a hill will easily hit 1100
Max on it is 1400 sustained with quick bursts to 1600 (very short)
As I'm told

I've asked around
The 1.6td is safe to 1100
Jon

[8v-of-fury]

yes, what psi are you cruising at when at 70+mph?

[nathan_b]

I have a frankenmotor with a k14, and now it has a k24, egts were lower on the highway with the k14, if there were no hills  at 70mph, egts would settle in 600f. 60mph would be 500f. I was running 20psi and max egt was like 1000f, and it was a reliable 9.5s 0-60. k24 was about 100f higher cruising and 200f higher max egt, but it WAS pushing 25psi...

I found the biggest thing unnecessarily raising egts on the highway is the smoke screw dumping unneeded fuel, is it in far?

also, small leaks between the turbo and manifold, mine broke the seal (after 10,000 miles ) and egts went up 150 across the board.

[R.O.R-2.0]

barron vonzepplin was running a n/a convert to 1250* sustained..

[punkvideo81]

8v-of-fury - Yes, it is Fahrenheit here in NY, & at 70+mph I would say boost is 5 or so psi, only comes up a lot if I give it moderate throttle at those speeds.

As for boost, I only see 19-20 psi if I floor it, which isn't often. I've only hit 1100-1200 degrees briefly a couple times accelerating uphills.
It behaves well and it responsive, I just want to see if I'm running the most efficient setup for for good power/cool temps with lots of driving. I feel like I need a bigger IC. The callaway gti IC I have is pretty small & I have an itching feeling the engine is getting more hot air than it should because it can't keep up.

[theman53]

I have a huge i/c and have about the same temps as you. Same boost as well at 70 ish on flat ground. Same giles pump and same 3 in all the way from the turbo. I don't have a tdi trans but I did put a 3.67 ring and pinion in my ags and its very high geared...I think we are just screwed. I am going to a different turbo soon hoping for change. 

[punkvideo81]

hmm, well at least this is some supporting evidence from a similar setup. thanks!