Upgrading fuel filtration on an IDI VW

[TurboJ]

OK, so there are some questions about fuel filtering on an IDI VW.

As most of you will know, I'm building a reasonably powerful 1.6 TD, and the monster VE pump on it requires an upgraded fuel system.
The pump is heavily modified and it needs extra cooling, for which it has been modified to also pump more fuel through it, not just to the injectors.
So I need to make sure the fuel filter doesn't cause unwanted pressure losses and damage the pump. I already have a fuel cooler, but the filter
must be one that flows well while still protecting the pump internals and the injector tips.

I have fitted bigger fuel lines and redone the in-tank fuel pickup system, see here: ( http://www.vwdiesel.net/forum/index.php?topic=17081.420 )

...so now is the time for the filter. So, some questions:

1. What is the micron rating of the OEM VW fuel filter - and is that rating nominal or absolute?
2. Tell me about your custom / Modified fuel filter assembly and how it's working / why you chose it.
3. Can you show me a picture of an early Bosch-style OEM spin-on filter assembly (as used on some mk1 IDIs) - what are its specs?

[TurboJ]

Also I would like to ask if my calculation is correct:

Supposedly a diesel engine uses approximately one gallon of diesel fuel per hour per every 18 horsepower produced.

So on a 250-hp diesel engine (safety margin there just in case) the maximum fuel flow to the injectors should be around 14 gallons per hour.

Correct?

[Gizmoman]

I did a quick google and ran across this on a tractor site:
"Models tested in 2000 averaged 16.5 hp-h/gal, compared to an average of 14.5 hp-h/gal for models tested in 1980." They were comparing efficiency improvements over the years. My guess is your numbers are pretty close. I believe the info was related to the tractors doing "work".

Regarding filtration and high GPM, if you want to stay fairly stock, maybe add several MK1 filters and "T" them together?

Not sure about the UM of off-the shelf filters. If high flow and extreme filtration (-2 um) is the goal, you may want to look at Parker or Bosch industrial hydraulic filters.

[theman53]

Apparently I lost all my figures. I had this done with the MK1 filter from Napa. They had down to 2 micron or something they also had 3 different variants that were a bit higher micron. They had all the filtration rates and everything. I will have  to do more digging. Basically, if you go to the parts store like I did and cross reference all the filters with the same diameter o ring and the same thread, then you can get the specs and see if they work. That is what I did.

[TurboJ]

Well, I work at a parts store and I have access to all the filter manufacturers' catalogs, all the reference numbers and the lot, but I still haven't found micron ratings anywhere 

GPH / LPH flow ratings are not there either. It's all just fitment and reference numbers.

I'm thinking of using a Bosch -style truck filter flange that takes a Bosch 1 457 434 154 diesel filter.
This would fit my newly-made filter flange holder and the space I have available.

BUT, I have no idea about the flow capacity and micron rating of this filter.
I do know that this filter is used on Deutz truck engines up to 350 kW ( 470 horsepower ), but I don't know how many there are on such an engine.
I suspect there are two, in which case my ~230 hp 1.6 could do well with just one such filter.

But, the problem is the filter needs to flow enough for all the cooling fuel flow the pump needs, not only enough to make the power safely.

[mtrans]

Dont trust me ,but I read standard filter is from 15-20 m,for golf 1 and 2.

[TurboJ]

That seems a logical rating as it would then match the rating of a period Merc diesel.

Can someone also tell me what are the thread sizes on a mk1 fuel filter flange? The one for the filter and those for the fuel lines as well.  Thanks!

******

I have now been browsing through this web page http://www.cficonnect.com/index.asp

But there is some very curious information around.

For my reference engine, a 470 horsepower Deutz diesel, it shows a reference to their product matching the Bosch 1 457 434 154 (Deutz's OEM fitment).
Filter specs are 10 microns and maximum flow of 6-8 GPM. That's 360-480 GPH !  WHAT? How could the flow be that high on a 5-inch high filter?

Then something even stranger. The list states that there is another filter option for this 470-hp engine - one with a water drain.
Guess what - that filter is the same as is used on the early 1.6 TDs - the mk1 diesel spin-on filter. And as this filter is rated at 14 microns,
its flow capacity is rated at 8-10 GPM, giving a theoretical maximum of 600 Gallons per hour.   

There you go, a mk1 OEM filter flows 600 GPH and is also used on a 470-hp truck engine. Wahey.

Of course, I suspect that truck has twin filters, but even then, this is quite something.

[TurboJ]

Update...

I have been cross-referencing all kinds of filters the entire day and now some of the night as well...

I thought you'd be interested to know that the mk1 diesel spin-on filter was also used on a Iveco Euroclass heavy truck of '93-> ,
the engine of which produced 278kW or 377 horsepower...

Both this application and the Deutz truck one above are listed as a single filter setup. This is not 100% certain of course, but Hengst's listing
states that there is only one fuel filter on each engine.

Now if we only knew how a late model mk2 diesel filter compares to these. That should be interesting! Too bad flow rates aren't
anywhere to be found and since the late model filters are VAG specific, there are no high-hp trucks using the same filters.

...and please share those mk1 diesel filter flange's fuel line connector port sizes, please!

[Gizmoman]

I didn't look too deep as far as micron size but I believe one of these may handle your flow requirements:
http://www.maesco.com/products/racor/r_spn_intro/r_spn_product/r_spn_product.html

[hillfolk'r]

Im not sure of micron rating,etc.
but the filter base is the same as a cummins b series dual fuel filter setup,the smaller secondary filter
its been years but i think its a fram ph 3528

[TurboJ]

Im not sure of micron rating,etc.
but the filter base is the same as a cummins b series dual fuel filter setup,the smaller secondary filter
its been years but i think its a fram ph 3528

...so on the Cummins, all the fuel flows through this secondary filter?
What type of injection system does this engine have?
And is there a separate transfer pump in that system?

[R.O.R-2.0]

stock 15m unit in the stock spot.

Racor 2 micron ahead of it..

works amazing..

[TurboJ]

Great job! Looks very good.

The problem is I must increase the flow capacity of my system, not decrease it.
Better filtration would be nice, but I can't use a filter system or combination that would add drag to the system.

[745 turbogreasel]

On my D24, I bolted a BMW 524TD filter and bracket to the OE spot in the block.  Its a nice filter with drain, water sensor, heater, and about 3X the volume of the stocker.
The D24T uses a regular IDI  filter from the factory, so that should be fine to at least 120HP.

[R.O.R-2.0]

Great job! Looks very good.

The problem is I must increase the flow capacity of my system, not decrease it.
Better filtration would be nice, but I can't use a filter system or combination that would add drag to the system.

thats why i added the lift pump behind the filters..

my pump is pressure fed, the vane pump is strictly for timing advance, not pulling fuel from the tank..

if i were to do it over again, i would use the next size bigger element..

i havent even had to change the first filter tho.. its been on there since like June of 2011, and im still running the same element, and it was USED when i got the filter..

i may even run 2 of these parallel on my next engine, i have 2 of these R120 filter bases and elements..

ive never ran the 2 micron without a lift pump, but i imagine it would result in less power and economy..