Plantoil/diesel conversion basics
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danalinscott

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Reply with quote  #1 

Caution....

TDIs need to be very carefully converted and purged.
Or they may end up like THIS ONE 



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Dana danalinscott@yahoo.com
Swany

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I just bought a 99 Jetta TDI and am looking to convert.  I helped a buddy convert his about a year ago and want to settle issues arising from his year of WVO before I settle on my system.  He was running HiH in series off of the cabin heater to a 3/8 copper coil on the fuel filter and and in the veg. tank in the trunk.  (He knows now that this system is underbuilt for heat to the VO.

Problems:

1) Coolant flow to veg system.

There was much too little flow through his system.  He was wearing blankets all winter!  This was helped by partially clamping off the coolant to the oil cooler.  How should  I plumb it and how can I reduce the drag or share the load between different coolant loops (ie the heater box and the oil cooler)???

2) Living in northern New England, what do I need to ensure I get my ~150 degrees even on the cold days?

dave


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Swany

99 Jetta TDI, Linscott hotrod, hoh, fphe, jacketed filter, inline heaters. Coolant plumbed in series with parallel loops for fphe and rest of rig.
danalinscott

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Hi Dave,

A series coolant circuit can be very restrictive to the coolant flow and so not allow enough coolant to flow to provide adequate heat to either the cabin heater OR the coolant heated VO conversion components.

I suggest using a parallel coolant circuit WITH a balancing valve istalled as shown in the top isllustration below.

I also suggest adding a FPHE to the configuration right before the filter if possible to add more heat to the VO prior to it reaching the IP. Finally..since TDIs are slow to warm up and you want to make certain that the VO reaching the injectors is as hot as possible I suggest adding Injector line heaters.

A forum with some discussion on injector line heaters is at:
 
The injector line heaters I use exclusively are available from:
http://lineheaterspecialists.netfirms.com/
 
More info:
A link with info related to this:
TDI Cold Weather mods

And examples of different coolant circuit configurations.



Posted 01 November 2007 06:41 PM

















Dana



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Dana danalinscott@yahoo.com
Swany

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Reply with quote  #4 
Thanks for this Dana. 

If I plumb the system parallel off the cabin heater loop, would it make sense to put some of the components on the cabin heater side of the parallel setup to create a more natural balance?

i.e.  I could run the hoh and fuel pickup on one loop and the cabin heater, FPHE, and filter jacket on the other side. 

Further question:  Keeping in mind that I'm in New Hampshire, if I run an FPHE before the filter do I need to jacket the filter, or could I just insulate it?  (Assuming I take your advice and install injector line heaters)





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Swany

99 Jetta TDI, Linscott hotrod, hoh, fphe, jacketed filter, inline heaters. Coolant plumbed in series with parallel loops for fphe and rest of rig.
danalinscott

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Posts: 934
Reply with quote  #5 

Quote:
If I plumb the system parallel off the cabin heater loop, would it make sense to put some of the components on the cabin heater side of the parallel setup to create a more natural balance?

i.e.  I could run the hoh and fuel pickup on one loop and the cabin heater, FPHE, and filter jacket on the other side. 


Yes..but I would recommend that you put the FPHE on its own circuit..and run an adjustable parallel loop off of that one to the filter jacket, HOH, and heated fuel pickup(in that order of flow).  On TDIs it has been reported that plumbing the FPHE into the cabin heater return hose in series seems to work best.

Does that make sense to you?

Quote:
Further question:  Keeping in mind that I'm in New Hampshire, if I run an FPHE before the filter do I need to jacket the filter, or could I just insulate it?  (Assuming I take your advice and install injector line heaters)


You will need to provide some heating to the filter to thaw it's contents initially. The coolant jacket wrap is the simplest way to do that. You will also want to remember to HOH and insulate all of the vo fuel line under the hood as well.

It is tight ...I know.

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Dana danalinscott@yahoo.com
Swany

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Reply with quote  #6 
It sounds to me like you are describing the final diagram in your series above.  Is that correct?  Two parrallel loops, one for FPHE, one for the rest plumbed in series into the cabin heater, correct?




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Swany

99 Jetta TDI, Linscott hotrod, hoh, fphe, jacketed filter, inline heaters. Coolant plumbed in series with parallel loops for fphe and rest of rig.
danalinscott

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Posts: 934
Reply with quote  #7 
Quote:
It sounds to me like you are describing the final diagram in your series above.  Is that correct?  Two parrallel loops, one for FPHE, one for the rest plumbed in series into the cabin heater, correct?


Yes..but balancing valves have been omitted from that schematic.

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danalinscott

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Reply with quote  #8 
Update...
I suggest adding Injector Line Heaters to any VW diesel conversion.
It is very important to make certain that the VO fuel is as hot as possible prior to injection with these engines. 

It is also very important to not switch over to VO before the engine is at full operating temp..and promptly switch back to diesel fuel if the t3emp drops for any reason.

And of course yo8u want to make certain that there is NO VO fuel/diesel mix that remains in the fuel system upon engine shutdown. Starting a cool engine on a VO/diesel mix is almost certain to result in significantly shorter engine life. And since most VW diesels tend to have high MPG it takse a long enine life to pay back the conversion investment.

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Dana danalinscott@yahoo.com
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