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  • Engine Exhaust gas temps

    OK,

    In response to Guys idea in yet another chip tuning thread, here's one on exhaust EGT's in turbo cars.

    The reason for this is when a car is "chipped", usually the boost pressure is raised. This usually results in higher Exhaust Gas Temps ( EGT's ) and this is a real concern for keeping your turbo intact. Too much heat is a sure fire way to blow your turbo.

    First up a petrol car runs higher EGT's than a diesel, thanks to higher combustion temps kindly suplied by your spark plug and richer fuel to air mixtures. A petrol car typically goes from rich ( too much fuel ) to towards optimal, whereas a diesel goes from lean ( too much air ) to towards optimal.

    We all have the same problem in a turbo car, and that is a ceiling on how much heat the turbo will handle. Especially a VNT variable vane non water cooled type.

    You can measure your EGT's in Vag com, I'm unsure of the exact block, but I found mine on channel 74 in the real time measuring under 01-engine in "select control modue". I'm sure it shows up in several spots, I'm still working out Vag com. You can find a suitable, out of the way, private test road, preferably a long steep hill, and log the EGT's etc in real time on a laptop. You can then download the data into excel and produce a plot and find some max EGT's ( and other things ) in your car as it stands. It's not super easy, and takes some fiddling, but I'm sure you can work it out.

    In my stock ECU GT TDI I have thus far observed a max of 819 degrees. This flies in the face of diesel guru's from the USA, who recommend a 700 odd max for their monster SUV diesels. Probably OK for the odd peak, and you REALLY have to thrash the TDI to get there, but it's still higher than I would have imagined. At idle the diesel is a tiny 160 degrees odd, but normal driving shows 400 plus pretty easily. DPF regen happens at 600 according to the manuals.

    The GTI / TSFI / TSI etc is going to run higher max EGT's, but the stock turbo is water cooled to counter this. Of that fact I'm jealous!

    Remember some people run turbo beanies or covers to keep the heat radiated from the exhaust side of the turbo out of their engine bay ( and thus air intake ) but this also keeps heat IN the turbine outlet, and keeps EGT's high.

    Be interested for anyone with real figures and ideas to add them, regardless of car. You R32 types can keep quiet thanks very much, this is turbo talk YO.
    Last edited by Greg Roles; 25-03-2009, 10:47 AM.
    2014 Skoda Yeti TDI Outdoor 4x4 | Audi Q3 CFGC repower | Darkside tune and Race Cams | Darkside dump pDPF | Wagner Comp IC | Snow Water Meth | Bilstein B6 H&R springs | Rays Homura 2x7 18 x 8" 255 Potenza Sports | Golf R subframe | Superpro sways and bushings | 034 engine mounts | MK6 GTI brakes |

  • #2
    From the other thread:

    No EGT probe required.

    For a start - you need to load the car (say on a petrol engine), you need a dyno capable of holding full sustained power for up to two minutes.

    say at 5500rpm, you will see the EGT's fluctuate up & down, and then after a period of time, they will stabilise & settle. This is the reading you need to work on.

    I will have to find out the measuring blocks for the EGT's on the TDI's - it differers per control unit.

    If you go into Vag Com (Hex USB + CAN) - into applications, and use the "controller channel maps" - put this in a spreadsheet & it identifies all channels that are able to be measured.
    sigpic

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    • #3
      Originally posted by cogdoc View Post
      OK,

      In my stock ECU GT TDI I have thus far observed a max of 819 degrees. This flies in the face of diesel guru's from the USA, who recommend a 700 odd max for their monster SUV diesels. Probably OK for the odd peak, and you REALLY have to thrash the TDI to get there, but it's still higher than I would have imagined. At idle the diesel is a tiny 160 degrees odd, but normal driving shows 400 plus pretty easily. DPF regen happens at 600 according to the manuals.
      This is probably because you have not loaded the car at max power to allow the EGT's to settle to their sustained maximum.

      A spike of 819 would be fine if you found it to settle under full load to say 700.

      As a side note, depending on the power output of a vehicle, some dyno's struggle to hold a sustained output long enough to get the EGT's to settle.
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      • #4
        Yeah, I agree Guy, but obviously about all "we mortals" can log on normal roads is the odd spike. Obviously a dyno like you have is the way to go. In real world driving you'd usually only spike at best, unless you live in the NT and happen to find a few km's of hill?
        2014 Skoda Yeti TDI Outdoor 4x4 | Audi Q3 CFGC repower | Darkside tune and Race Cams | Darkside dump pDPF | Wagner Comp IC | Snow Water Meth | Bilstein B6 H&R springs | Rays Homura 2x7 18 x 8" 255 Potenza Sports | Golf R subframe | Superpro sways and bushings | 034 engine mounts | MK6 GTI brakes |

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        • #5
          The next best way would be a load based road log - find the biggest, sustained hill you can (nice mountain drive) and try to run it up a gear higher than normal (ie - really load the car up).

          You will be amazed at the data differences to a flat road third gear pull!

          It would still be nice to hold that full sustained power for at least a minute or more (difficult to keep it under the speed limit).
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          • #6
            Can you offer that on your dyno Guy? Might be time to do exactly that.
            2014 Skoda Yeti TDI Outdoor 4x4 | Audi Q3 CFGC repower | Darkside tune and Race Cams | Darkside dump pDPF | Wagner Comp IC | Snow Water Meth | Bilstein B6 H&R springs | Rays Homura 2x7 18 x 8" 255 Potenza Sports | Golf R subframe | Superpro sways and bushings | 034 engine mounts | MK6 GTI brakes |

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            • #7
              Originally posted by Guy_H View Post
              The next best way would be a load based road log - find the biggest, sustained hill you can (nice mountain drive) and try to run it up a gear higher than normal (ie - really load the car up).

              You will be amazed at the data differences to a flat road third gear pull!

              It would still be nice to hold that full sustained power for at least a minute or more (difficult to keep it under the speed limit).
              Out of interest Guy, does the K03/K04 have some sort of protection to prevent overheating?

              It is watercooled, isn't it? I'm sure I can hear some sort of pump going when I turn off the engine.......

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              • #8
                We have (only hired, but had it installed & been trained on) a new AWD Mainline dynolog dyno. When we get a premises that we can install one into, this will more than likely be our chassis dyno of choice.

                It has excellent ramp up settings that will step up or down the load & it holds it extremely well.

                Problem is, we have been on it 12 hours a day for the past week (doing calibration) & I don't know how much spare time we will get when (& if) we finish calibration on this trip (I have three APR engineers here for the month).
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                • #9
                  Originally posted by kryten2001 View Post
                  Out of interest Guy, does the K03/K04 have some sort of protection to prevent overheating?

                  It is watercooled, isn't it? I'm sure I can hear some sort of pump going when I turn off the engine.......
                  Two things: Firstly the turbo is both water & oil (oil also used for lubrication) cooled - and yes, when you shut it off, there is a temp sensor which will run an Aux cooling pump which cools down the turbo & engine even if you have locked the car up. You will even sometimes hear the engine fans kick on if the temp is too high for coolant only.

                  On the FSI cars - there is a "Hardware Protection" level, that richens the mixture considerably to col the components down.

                  You can see this on a dyno at WOT, the A/F mixture will drop down to about 11 ~ 11.5:1 .

                  This is obviously only a dyno sweep as well, but is a guide to the shorter term strategies of the map to cool components down.

                  You can see some dyno's from a thread on the dyno day in Sydney recently (happens to be the same dyno we hired), and the difference in a couple of tunes and how they make power & torque.

                  You will see the car that can not control A/F mixture makes very low torque compared to some of the others, although the peak HP is pretty similar. It is running very lean to make that peak HP, the other two are running factory A/F mixtures.

                  Keep in mind, I only have the dyno sheets, there may have been a problem with the car or the measuring device.

                  If you can imagine the long term effects of these mixtures on your components.

                  The dyno plots are here:

                  Performance Mods: APR STAGE 1+2, EVOMS Intake, APR 3inch TBE DYNO:


                  Forget the TDI plot
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                  • #10
                    Here's my graphs. I don't have access to a dyno, they were done in 3rd gear on a circuit (ie. flat). There wasn't enough room to do 4th gear or higher. They may not be of much use as the car wasn't loaded up to the max for a sustained period, but realistically this is the toughest kind of driving my cars are likely to see. Two different cars, both with the 2L TFSI (petrol) engine.

                    First, stock vs Bluefin (forgot to log stock exhaust temp, sorry)



                    Then, stock vs ST3 Fast road map

                    Last edited by mrx; 25-03-2009, 01:04 PM. Reason: Spelling

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                    • #11
                      Thats a good start!

                      Just as an example of how different sustained temps are: We had to build an exhaust extraction duct for the dyno this week.

                      We have been running a 1.4 Twincharger on the dyno for 4 days, we have probaly done 60 + power runs (similar to what you do on a dyno day) - we then did one EGT load run, about 45 seconds full throttle.

                      That one run melted our high temp insulated exhaust ducting two feet from the exhaust
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                      • #12
                        Originally posted by Guy_H View Post
                        Two things: Firstly the turbo is both water & oil (oil also used for lubrication) cooled - and yes, when you shut it off, there is a temp sensor which will run an Aux cooling pump which cools down the turbo & engine even if you have locked the car up. You will even sometimes hear the engine fans kick on if the temp is too high for coolant only.
                        So what's your experience in turbo longevity given these aggressive APR tunes?

                        Is a lot of WOT throttle a bad idea? Should we be reserving this lunacy somewhat to better look after our turbos/engines?

                        I'll temper the constant WOT's if that's the case...

                        Nearly 1000 degrees.. Good lord.. That's 3/4's the way to the melting point of iron!


                        Cheers.

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                        • #13
                          speaking of EGT, Bluefin just released their 251 kw (337 hp) stage 3 kit for the Pirelli,ED30... and get this it needs : intake , high flow Cat, Full exhaust optional !, APR Fuel pump !. as tested.. 251 kw. 336 Hp. 433 NM id like an EGT temp read of that. TSSSSS thats for a pretty quick car though.
                          MY 12.5 Golf R
                          09 Pirelli GTI sold
                          09 A6 2.0T

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                          • #14
                            Hey Andew - get on the Autobahn & hold it flat out for 10 minutes!

                            No problems expected at all with longevity, as the EGT's (only one component) are well withing Borg Warners factory spec.
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                            • #15
                              Originally posted by Edra View Post
                              speaking of EGT, Bluefin just released their 251 kw (337 hp) stage 3 kit for the Pirelli,ED30... and get this it needs : intake , high flow Cat, Full exhaust optional !, APR Fuel pump !. as tested.. 251 kw. 336 Hp. 433 NM id like an EGT temp read of that. TSSSSS thats for a pretty quick car though.
                              Hi Edra,

                              I would love to see that - we use similar components in our 240kw kit:



                              But even that - the exhaust is not "optional", and an intercooler is recommended.

                              I would love to see some testing data of that version! especially on how they expect to see near that HP with that turbo & exhaust!
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