Hi Martin,
Please see #### for my comments:

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

- Vanagon Accessories and Engine Conversions
- Vanagon, Transporter and Iltis Sales and Importation
- European Lighting for most Volkswagen models

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-----Original Message-----
From: Martin Jagersand [mailto:jag@cs.ualberta.ca]
Sent: May 31, 2005 5:54 PM
To: mailinglist@FASTFORWARD.CA; vanagon@gerry.vanagon.com
Subject: Re: Hi-Power TDI Vanagon observations

Hi David,

Your hi powered TDI observations are quite interesting. Especially
that you can keep it cool enough despite the increased power.

FYI: My 1.9TD has nearly the same EGT readings: around 400C
at 100-110 km/h highway and up to 800C in long hard climbs.

Jake Russell who was active on the Diesel list several years
ago found that there was a direct coupling between EGT change
and intercooler efficiency. Ie at 15psi boost the post turbo
temp is often in the 100C range. Using an oversized intercooler
(Jake found that the Audio 5000 one worked quite well, but it's
a lot bigger than the TDI one), the post IC temp can be brought
to almost ambient (e.g. 20C). Then measuting EGT with and without
intercooler the EGT dropped nearly the same amount as the intake temp.

#### I agree, Oil temperature and Intake Air Temp play rolls in the EGTs

I tried to put the big Audi 500 IC in my Vanagon setup, but it
is a tight squeeze, and I never found a good reliable solution.
(Same setup as yours with IC behind drivers side tail light).

#### I am using a Jetta III intercooler with my motor with a 8" PermaCool
fan behind it.  According to VAG-COM, it is more efficient than the
intercooler was in the Jetta III.  The Audi 5000T intercooler is quite big
and hard to mount in a place where you can ram air through it.

I was curious if you have before and after IC temps for different
boost pressures and airflows through the IC?

#### Before is easy - atmospheric temp, after is no more than 60 to 70C

How do you wire your IC fan? Always on? Or temp controlled?
At highway speeds does it need to be on? (I'm thinking there might
be a pretty good airflow through the air channel anyway)

#### The fan comes on when the ECU turns on and it is constantly on.  At
highway speeds it needs to be on - one day I had a relay for the fan pack it
in and the engine was not happy - kept on getting over boost errors... a fan
is necessary!  :-)

Cheers,
Martin