Driving with Power Boxes

Hello!

Could some of the people who have a powerbox briefly describe the behavior of their car? For example, smog might not be visible during the day, but a haze might be noticeable in the rearview mirror while driving on the highway?

Yesterday, I noticed a strong haze or veil in the rear-view camera's view while driving my car (Speed-Buster II) on the highway. This haze only appears when I initially accelerate, but it almost disappears after about 2-3 seconds. There's absolutely nothing to see during the day.
Is there a lot of Russian gas accumulating in the exhaust that needs to be blown out first? Perhaps the amount of fuel entering the intake manifold is increasing faster than the turbocharger can generate sufficient boost pressure.

I'm quite concerned about whether I'm already approaching the limit of potentially harmful performance gains. The Ulf-test result was 4.4, and the torque curve with the Speed-Buster is likely different from the stock curve, which makes it difficult to estimate the horsepower. Currently, the Excel sheet shows approximately 140 horsepower and 300 Nm of torque, which I believe is an overestimated value.

Well, some people have a lot of experience with boxing (like Rainer, for example). Sure, I'm looking forward to your response.

Best regards, Georg.

Hello Georg,

"Achieving 140 horsepower is quite feasible, and here's my experience regarding soot emissions:"
- At approximately 1 bar of boost pressure and with a setting of around 135-140 horsepower, I noticed a slight whistling sound under full throttle. During the day, it was only visible as a dark veil in the rearview mirror, but at night, in the headlights of following vehicles, I felt really bad .
- With slightly modified intake manifolds (as described in archives 2 and 3 of the old forum), and a boost pressure of 1.1 - 1.2 bar, nothing is visible anymore, even in the dark. The engine is tuned to produce over 140 horsepower.
Despite the prolonged city driving and subsequent full-throttle acceleration, a small puff of smoke was visible, which I, however, consider to be insignificant.

Best regards, Rainer.

Hi,
'TDi engines typically run with an excess of approximately 20% air. Therefore, it's not surprising that the car starts to produce black smoke when the power is increased by nearly 30%.' If you can't/don't want to adjust the boost pressure, I would adjust the tuning until it stops producing excessive smoke.

Perhaps I should mention that, in my opinion, excessive soot buildup can, in the long term, lead to difficult VTG adjustment.

Georg_G wrote:

Hello! Could some of the people who have a powerbox briefly describe the behavior of their car? For example, smog might not be visible during the day, but a haze might be noticeable in the rearview mirror while driving on the highway? Bitte gib den Text an, den du übersetzt haben möchtest. I'm quite concerned about whether I'm already approaching the limit of potentially harmful performance gains. The Ulf-test result was 4.4, and the torque curve with the Speed-Buster is likely different from the stock curve, which makes it difficult to estimate the horsepower. Currently, the Excel sheet shows approximately 140 horsepower and 300 Nm of torque, which, in my opinion, is an overestimated value. .

Hi Georg,

my e-scooter (even in the relatively weak factory setting / about 5 horsepower) also produces noticeable soot in the headlight beam of the following vehicle when I give it the first burst of acceleration, while nothing is visible during the day.
However, even when the device is running at a higher setting or with the box turned off, the soot pattern does not change significantly.

Are you absolutely sure that your acceleration times weren't measured under "too favorable" conditions – such as with small tires (rolling circumference measured?), a slight downhill slope, or speedometer/ DZM advance, etc.?
"4.4 seconds would, in my opinion, be an incredibly good time under normal conditions. Based on my calculations, it would indicate approximately 152 horsepower / 325 Nm of torque, which, even without increasing boost pressure, would likely result in noticeable soot emissions."
However, even with the smallest tires within the tolerance, a 1% incline, and a 20 km/h tailwind, you would still need approximately 138 horsepower / 295 Nm of torque, which, with a "brutal" tuning, might just be achievable without excessive soot.

Hi,
Could someone be kind enough to calculate my engine power for me using Excel? I'm having trouble figuring it out. I can only state the measured time it took to complete the process.

Approximately 6.7-6.8 seconds from 2000-4000 RPM.
Passat Variant 1Z, tires size 205/50-15.

Thank you.

Thank you for the answers.

I'll probably adjust the air box a bit further, or adjust the I-screw, which controls the influence of the mass airflow sensor, slightly towards "fuel injection starts at a higher airflow rate." I'm curious to see if this noticeably changes the rough running behavior. Ulf's contribution doesn't give me much hope, especially if I want to maintain a noticeable performance improvement.

What's interesting is that I've only managed to adjust the box by about 0.7 revolutions from its "original" factory setting, where I couldn't measure any performance gain, and this adjustment is on a spindle trimmer that has a total of 25 revolutions.

The 4.4-second times were recorded on the exact same track (3 measurements, the same one used for the 5.8-second time in stock condition). Don't forget that my vehicle's unladen weight, according to the vehicle registration document, is only 1098 kg. I'm also surprised by this very low time.
With a 600-ohm resistor between pins 2 and 3, I once achieved 4.8 seconds, but at that point, the torque pushed me firmly into the seat at 1900 rpm.
The current driving experience is completely different; the maximum torque is estimated to be between 2100 and 2200 rpm, whereas before it only exhibited standard behavior.

Best regards, Georg.

Hello, the most important piece of information is missing from your details, which is the weight of the vehicle at the time of the measurement.

Best regards, Rainer.

tim27 wrote:

Hi, Could someone be kind enough to calculate my engine power for me using Excel? I'm having trouble figuring it out. I can only state the measured time it took to complete the process. Approximately 6.7-6.8 seconds from 2000-4000 RPM. Passat Variant 1Z, tires size 205/50-15. Thank you.

Hi,
Thank you for your effort. It seems I weigh 1285 kg + approximately 35 kg of diesel + 80 kg of my own weight.

According to the tuner, the engine should produce approximately 122 horsepower and 300 Nm of torque. Does that sound right?


'Please provide the text you would like me to translate from German to English.'

tim27 wrote:

Hi, Thank you for your effort. It seems I weigh 1285 kg + approximately 35 kg of diesel + 80 kg of my own weight. According to the tuner, the engine should produce approximately 122 horsepower and 300 Nm of torque. Does that sound right? thank you.

. . . or the translations from the 3rd of [month/date]. "Operation and the rear-wheel drive system."
Only then can one reasonably estimate the approximate horsepower.

Best regards, Ulf.

Georg_G wrote:

. . . The 4.4 seconds were recorded on the exact same track (3 measurements, the same one used for the 5.8 seconds in the stock condition). Don't forget that my vehicle's unladen weight, according to the vehicle registration document, is only 1098 kg. I'm also surprised by this very low time, however.

Hi Georg,

Reducing the mass by around 100 kg can result in approximately 0.5 seconds faster times. This would be a significant improvement, even without any additional "performance boost." I'm surprised by the weight, especially since the Ibiza with 110 horsepower is listed in the catalog with a weight of 1,200 kg.
What did you enter as the maximum permissible weight?

Hi Ulf, hi Georg,

The 1200 kilograms refers to the "basic equipment," whatever that may be, because the more powerful versions usually also have more "extras" that add to the weight.

My Ibiza (slightly newer than Georg's, but also with ASV) is registered at 1240 kg. It has weight-adding extras like climate control and electric windows. I suspect that with AHK, he would get quite a bit closer to George's car.

What kind of features does it have, Georg?

Best regards,

Jan.

Hello Ulf,
Okay, I think I have an ASD transmission, and it's the 3rd gear. The exchange rate for the Gang is 1.308 (and compared to CTN, the exchange rate is 1.360).

Hello Jan, Ulf.

The equipment includes Signo features, such as automatic climate control and power windows, along with all the other standard features. If this engine had been available without all the extra features in this car, I would have preferred it without those features.

Maximum authorized gross weight is 1585 kg, unladen weight is 1098 kg, resulting in a payload capacity of 487 kg. Everything is in kilograms, not in imperial stones or anything like that.

With 1098 and 110 horsepower, the Ulf-Excel spreadsheet shows an acceleration time of exactly 5.8 seconds. My own measurements also show an acceleration time of exactly 5.8 seconds. That's an indication that the unladen weight is actually around 1100kg.


Automotive greetings :-]

Georg.

tim27 wrote:

Hello Ulf, Okay, I think I have an ASD transmission, and it's the 3rd gear. The gear ratio is translated to 1.308 (and compared to the CTN transmission, it is 1.360).

Now, only the axle ratio (differential) is missing, and then you can start with the calculations...

Hello everyone.

Quote:

The equipment includes Signo, which means automatic climate control, electric windows, and all the other extras. If this engine had been available without all the extra features in this car, I would have preferred it without those features. Maximum authorized gross weight is 1585 kg, unladen weight is 1098 kg, resulting in a payload capacity of 487 kg. Everything is in kilograms, not in imperial stones or anything like that. With 1098 and 110 horsepower, the Ulf-Excel spreadsheet shows an acceleration time of exactly 5.8 seconds. My own measurements also show an acceleration time of exactly 5.8 seconds. As a

clue, it suggests that the unladen weight is actually around 1100kg.

Yes, the bill is correct.
The maximum weight of 1,585 kg matches the information in the German catalog.
ASV Signo makes me suspect a re-import, similar to what happened with Jan (country??), except that he registered a higher empty weight - AND, if I remember correctly, he also recorded correspondingly longer transit times. It's still kind of strange...

I also measured the acceleration of my wife's ALH-Ibiza, and I got a result that was about 0.6 seconds "too low," which could be explained by the fact that it weighs 80 kg less than the catalog specifications – or by approximately 6 horsepower more .