In January 2010 we bought a VW Touran 1,9TDI, installed a Diesel Particulate Filter, and will convert it with a 1-tank(DI-PD)  system. The Touran is replacing the Golf, which has done very well during more than 10 years. With the Touran we can demonstrate the latest technology within 1-tank systems for unit injection engines, and PPO operations with particulate filter.

Converted with an ELSBETT TDI 1-tank system. The car has a 5kW comfort heater installed, supplied with diesel from a seperate tank. Pre heating the engine with the comfort heater 10-15 minuttes at winter time enables the engine to start promptly and burn efficient from the start. Alternatively to the pre heating by the comfort heater, 10-15% diesel could be mixed with the PPO in the winter season. In the spring, summer and autumn it´s not necesary to pre heat the engine with the comfort heater, or to mix PPO with diesel.

See also Power curve on PPO

Maintenance and service:

• changing lube oil and filter each 7.500km (½ interval due to direct injection engine and 1-tank system)
• Adding O-ring at the return valve on the fuel filter because of problems with air in the fuel.
• EGR valve cleaned in July 2006. Symptoms was reduced power and permanent smoking even at medium load.
  (EGR: Exhaust Gas Recirculation, leads exhaust gas back to the air intake during medium load. The valve often fails on older engines by hanging in open position, which leads to building up of more deposits on the EGR valve, in the air intake, on the piston and piston rings, inlet and outlet valves etc. )
• Diesel Particle Filter installed january 2010.

Fuel consumption:

• 12km/l by "fresh" driving.

Situation of fuel filter and heat exchanger(example)
 

Situation of diesel tank for comfort heater

Converted with an ELSBETT IDI 1-tank system. The engine has remarkable more torque on PPO than on diesel, and therefor the fuel consumption might be a little higher on PPO than on diesel.

See also:

• video with cold start at -10°C
• power curve
• Report from technical inspection (danish)
• photo´s of the conversion

Maintenance and service:

• changing lube oil and filter each 10.000km, using semi synthetic lube oil 10W40.
• Changing fuel filter each 25.000-35.000km
• else just normal maintanence.
• after 150.000km on PPO(totally 400.000km), 1 glow plug was broken(all 4 was changed), and the sealing at the drive shaft of the injection pumps was changed because of air in the fuel.

Fuel consumption:

• 15 km/l at average speed
• 17 km/l at long trip  at ~ 110km/h
• 12 km/l at long trip at ~ 140 km/t

Converted with an ELSBETT IDI 1-tank system, and has not filled a single drop of diesel since 1999.

There was not notised any diffenrence in power and consumption between PPO and diesel.

For the long trips some extra 85 liters of PPO can be brought in the car, enabling the car to run 2600-3000km on a full tank including the extra fuel. If the trip pass Germany, there are many possibilities to buy PPO on the way. See list of German PPO filling station and fuel suppliers.

See also:

• Video with cold start at -3°C

Maintenance and service:

• changing lube oil and filter each 10.000km, using semi synthetic lube oil 10W40.
• Changing fuel filter each 25.000-35.000km
• sealing at the actuator for speed regulation at the injection pump changed after 1 year on PPO.
• else just normal maintanence.

Fuel consumption, examples:
Winter:
- 3100 km long trip inlcuding mountain roads in the Alps. 6 days with cold start at -5°C to -9°C. Coldest driving temperature -13°C. Average consumption for this trip 17,3 km/l.
- Average consumption at winter: 17 km/l

Spring
- 980 km long trip at 120 km/h with full load: 18,2 km/l
- 1300 km long trip at 100-110 km/h with half load: 20,2 km/l

Summer:
- 5340 km long trip at 100-130 km/h, incl. mountain roads and cities : 20,5 km/l
- average consumption at summer: 19,5km/l.