HE200 and Giles 1.6 IP in a 1.9 AAZ Vanagon

[410]

Always nice to hear a success story.  Good work Jim.  It's about time you get to enjoy all your hard work with a little holiday. 

[Gizmoman]

Great news!

Have a safe trip Jim

x2
Pretty nerve-wracking to be troubleshooting right before a big trip...been there, done that.

It's been nerve wracking for sure - and the "personalized" camper is a big part of the adventure. I believe it will enjoy the two lane backroads and cool mountain air as much as we will. My two biggest worries now are the weird jog I had to fab in the boost pot linkage and the transmission getting hammered from the extra oompf.

If that pot rod breaks, I spoze I will be S.O.L. Possibly some bailing wire to hold the gate closed will keep me going. If the tranny craps out though, It's over. I need to keep my foot out of it.

I'd be in a real mess without this forum's help. Thanks to all

[RabbitJockey]

awesome.  i remember when my wastegate was stuck shut i could easily control max boost with the max fuel screw, also makes a huge effect on spool up.

[Alcaid]

My friend just tested an HE200WG turbo just like the one you are running on his 1.6TD, fully built 11mm pump, ported head, bigger intake valves etc etc. He hit 51psi of boost before turning down the boost controller somewhat, a little bit too much for a single stage turbocharger in the long run maybe

[jmaddocks]

My friend just tested an HE200WG turbo just like the one you are running on his 1.6TD, fully built 11mm pump, ported head, bigger intake valves etc etc. He hit 51psi of boost before turning down the boost controller somewhat, a little bit too much for a single stage turbocharger in the long run maybe

Holy crap!  Stock bottom end?

BTW, I started wondering if my WG was blowing open...turns out it was.  I added some preload, and we're hitting (and maintaining) about 27-28 psi with EGT generally staying below 1200 F.  Very happy.

[Alcaid]

Rosten Performance H-Beam rods (big end of those are modified to run the wider TDI rod bearings)

[jmaddocks]

Nice!

My two biggest worries now are the weird jog I had to fab in the boost pot linkage and the transmission getting hammered from the extra oompf.

Rather than having a jog in the WG linkage, you might want to consider relocating the WG diaphragm instead, and keeping the stock Holset straight linkage.  Our diaphragm is offset to one side of the original mounting location using a short piece of angle iron that goes across both mounting tabs and cantilevers off of them. There's quite a bit of preload (maybe 20-30 lbs?) in the actuator, and I'd be worried a jog would make it too springy. 

Probably a huge PITA at this point, but I thought I'd throw it out there.

[sdubfid]

they make the holset in different configurations and even one that looks like it would work like the oem k14 setup

[Gizmoman]

Just returned from our two week camping trip up the East Side of the Sierra Nevadas. We camped at several lakes on the East side and ended up at Tahoe. Then back down the West side camping at a few more lakes on the way.
Van fully loaded weighed 4800 lbs on the truck scales (a lot less than I thought). There were probably ten or more 5-7% grades longer than 20 miles each - a real test of the contraption.

I kept the EGTs below 1150 most of the time with a few stints at 1350 F. Water temp never went over 215F (made sure of that with my right foot). I kept my speed to 65 most of the time with a few runs at 70 going through LA.
Highest elevation was 11,500 ft. I should mention here that my boost gauge read -3 psi at the higher elevations.

When I left, I had removed my DIY boost controller and turned in the LDA screw almost 1/4 turn which really helped with low end. I also turned in the fuel screw 1/4 turn and backed off the idle as far as it would go. Boost seemed to dump easily around 14 psi. Twice I added tension to the adjustable gate rod trying to keep from dumping boost early.

I then backed off the LDA screw 1/8 turn and the fuel screw the same amount. This seemed to lower EGTs a bit but boost was still not what I was hoping for. I finally took some mechanic's wire and pulled the gate shut permanently. I disconnected the boost pot entirely and plugged the "T". This seemed to finally lower EGTs some and I can hit 20 psi but only at WOT. I still think something's off with my fuel to boost relationship but it's much more acceptable now.

The trip was fantastic and overall the engine performed flawlessly. It used 1/3 quart of oil over 1500 miles and I believe most of that was due to a few small leaks I can't seem to fix entirely. I have my vent from the hockey puck piped to a clear plastic bottle and it's got about a 1/4 teaspoon of oil in it .

Loading up. . .


Off the bow of the kayak in the early morning - Silver Lake, CA (just above June Lake). . .
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Thanks to all of you for the wonderful assistance!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[Rock3tman]

4800 lbs + that kayak @ 65mph...just WOW!!    Do you have an idea of what your overall/best/worst MPG was?

the lake picture says it all - - congratulations on the build.

[Gizmoman]

4800 lbs + that kayak @ 65mph...just WOW!!    Do you have an idea of what your overall/best/worst MPG was?

the lake picture says it all - - congratulations on the build.

The weight included the kayak - I thought I'd be closer to 5800 myself. Besides, the wife had every nook and cranny stuffed with something

Best mileage was a sad 22 mpg - average was 20. I was hoping for more but it's shaped more like a toaster than a Lamborgini. Sleeping is better though

[libbydiesel]

Hmmm. I average better than that in my high top while towing a loaded trailer.

[theman53]

For mileage that bad you must be boosting all the time. Mine got a few 28mpg when I was taking that trip to SD, but the entire tank was 7-10psi, if I keep it under 5psi I get low 40s mpg.

[Gizmoman]

Hmmm. I average better than that in my high top while towing a loaded trailer.

For mileage that bad you must be boosting all the time. Mine got a few 28mpg when I was taking that trip to SD, but the entire tank was 7-10psi, if I keep it under 5psi I get low 40s mpg.

I am running a guestimated average boost of 6-8 psi most of the time. The K-14 ran around 10. The only way I could keep the boost under 5 would be to stay on side streets and never go over 35.

Any clue what the cause may be? I have a lift pump that I should remove, but from what I've read, it doesn't change the IP output enough to worry about.

I do run low boost - just not often. Here is a shot running along the 395 North. Flat with a very slight tailwind. . .

63 MPH, 4 psi, 876 EGT, Oil pressure 23 (the OP is not correct - actual is closer to 33 psi - new gauge on order)

I'm sure my milage would be better if I stayed around 50-55. If I had to do that, I'd just sell it.

[libbydiesel]

Just for reference, a vanagon getting 20 mpg is about the same as a jetta getting 30 mpg.