Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on April 5, 1985.
As of Wednesday, October 23rd, 2019 this Executive Order has not been overturned or superceeded.

Approved Parts

Part NumberModelsModification
VW-341984-1985 VW Jetta, Rabbit, and Scirocco powered by a 1.8L fuel injected engineStatic ignition timing is set to 3 degrees BTDC, add check valve to PCV

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-155
  • Executive Order 155 / D155
  • ARB # D-155
  • Executive Order No: D-155
  • C.A.R.B. No. D-155
  • Resolution D-155
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-155 PDF

D-155 Document:



                                                       (Page 1 of 2)
                              State of California
                              AIR RESOURCES BOARD

                             EXECUTIVE ORDER D—155
                  Relating to Exemptions under Section 27156
                              of the Yehicle Code


                              LEGEND TURBO INC.*‘S
                        MODEL Y¥W—34 TURBOCHARGER SYSTEM


Pursuant to the authority vested in the Air Resources Board by Section 27156
of the Vehicle Code; and

Pursuant to the authority vested in the undersigned by Sections 39515 and
39516 of the Health and Safety Code and Executive Order G—45—5;

IT IS ORDERED AND RESOLYED:   That the installation of the Model YW—34
turbocharger system manufactured by Legend Turbo Inc. has been found not to.
reduce the effectiveness of required motor vehicle poliution control devices
and, therefore, is exempt from the prohibitions of Section 27156 of the
Yehicle Code fo 1984 and 1985 model—year Yolkswagen Jetta, Rabbit, and
Scirocco models equipped with 1.8 liter fuel—injected engines.

This Executive Order is valid provided that installation instructions for this
device will not recormend tuning the wehicle to specifications different from
those submitted by the device manufacturer.

Changes made to the design or operating conditions of the device, as exempted
by the Air Resources Board, that adversely affect the performance of a
vehicle‘s pollution control system shall invalidate this Executive Order.

Marketing of this device using an identification other than that shown in this
Executive Order or marketing of this device for an application other than
those listed in this Executive Order shall be pronibited unless prior approval
is obtained from the Air Resources Board. Exemption of a kit shall not be
construed as an exemption to sell, offer for sale, or advertise any component
of a kit as an individual device.

This Executive Order does not constitute any opinion as to the effect that the
use of this device may have on any warranty either expressed or implied by the
vehicle manufacturer.

THIS EXECUTIVE ORDER DOES NOT CONSTITUTE A CERTIFICATION, ACCREDITATION,
APPROVAL, OR ANMY OTHER TYPE OF ENDORSEMENT BY THE AIR RESQURCES BOARD OF ANY
CLAIMS OF TNE APPLICANT CONCERNING ANTI—POLLUTION BENEFITS OR ANY ALLEGED
BENEFITS OF THE LEGEND TURSO INC.‘S MODEL VW—34 TURBOCHARGER SYSTEM, WHICK IS
EQUIPPED WITH A TURBOCHARGER THAT HAS AN A/R OF 0.59.


LEGEND TURBO INC.*‘S                               EXECUTIVE ORDER D—155
MODEL yW—34 TURBOCHARGER SYSTEM                         (Page 2 of 2)



No claim of any kind, such as "Approved by Air Resources Board" may be made
with respect to the action taken herein in any advertising or other oral or
written communication.

Section 17500 of the Business and Professions Code makes untrue or misleading
advertising unlawful, and Section 17534 makes violation punishable as a
misdemeanor.

Section 43644 of the Health and Safety Code provides as follows:

         "43644.   (a)}   No person shall install, sell, offer for
         sale, or advertise, or, except in an application to the
         state board for certification of a device, represent, any
         device as a motor vehicle pollution control device for use
         on any used motor vehicle unless that device has been
         certified by the state board.    No person shall sell, offer
         for sale, advertise, or represent any motor vehicle
         poliution contral device as a certified device which, in
         fact, is not a certified device. Any violation of this
         subdivision is a misdemeanor."

Any apparent violation of the conditions of this Executive Order will be
submitted to the Attorney General of California for such action as he deems
advisable.

                                              [.
Executed at El Monte, California, this    SS*:LL day of April, 1985.



                                         /222¢é1'<:;,   e
                                         K. D. Drachand, Chief
                                         Mobile Source Division


                             State of California
                             AIR RESOURCES BOARD




EVALUATION OF LEGEND TURBO INC.‘S MODEL VW—34 TURBOCHARGER SYSTEM FOR
EXEMPTION FROM THE PROHIBITIONS IN VEHICLE CODE SECTION 27156 IN ACCORDANCE
WITH SECTION 2222, TITLE 13, OF THE CALIFORNIA ADMINISTRATIVE CODE




                                 April 1985


                                                   Date of Issue:   April 1985




EVALUATION OF LEGEND TURBO INC.‘S MODEL VW—34 TURBOCHARGER SYSTEM FOR
EXEMPTION FROM THE PROHIBITIONS IN VEHICLE CODE SECTION 27156 IN ACCORDANCE
WITH SECTION 2222, TITLE 13, OF THE CALIFORNIA ADMINISTRATIVE CODE




                                      by
                            Mobile Source Division

                             State of California
                             Air Resources Board
                             9528 Telstar Avenue
                             E1 Monte, CA 97131




{This report has been reviewed by the staff of the California Air Resources
Board and approved for publication. Approval does not signify that the
contents necessarily reflect the views and policies of the Air Resources
Board, nor does mention of trade names or commercial products constitute
endorsement or recommedation for use.)


                                      SUMMARY



         MCD Associates, Inc. has requésted an exemption from the prohibitions in

Vehicle Code (¥.C.) Section 27156 of the Legend Turbo Inc.‘s {LTI} Model YW—34
turbocharger system for installation on 1984 and 1985 model—year Volkswagen

Jetta, Rabbit and Scirocco models equipped with 1.8 liter fuel—injected

engines.

         The applicant submitted a comprehensive application package including

comparative emissions test data, exhaust temperature study data, warranty

statement, installation/maintenance procedures, and packaging/identification

labels.     The applicant also provided a test vehicle for confirmatory emissions

tests.
         Based on the submitted information and the results of exhaust emission

tests performed by the applicant at an independent laboratory on a 1984

Volkswagen Jetta (49—State Certified), and of the confirmatory tests performed

by another independent laboratory and the Air Resources Board‘s Haagen—Smit

Laboratory on a 1984 VW Scirocco (California Certified), the staff concludes

that the Legend Turbo Inc.‘s Model VW—34 turbocharger system will not

adversely affect exhaust emissions from the specified vehicles.

         The staff recommends that LTI be granted a ¥.C. Section 27156 exemption

as requested and that Executive Order D—155 be issued.


                                   CONTENTS



                                              Page Number



SUMMARY

CONTENTS                                          11



I.     INTRODUCTI ON

II.    CONCLUSTON

III.      RECOMMENDATION




                                                  h
IV.    LTI MODEL VW—34 TURBOCHARGER SYSTEM




                                                  No
V.     EMISSION TEST DATA




                                                  o_
¥I.       DiSCUSSION




                                                  ~—
VII.   APPENDICES                                 11




                                      i1


EVALUATION OF LEGEND TURBO INC.‘S TURBOCHARGER SYSTEM FOR EXEMPTION FROM THE
PROHIBITIONS IN VEKHICLE CODE SECTION 27156 IN ACCORDANCE WITH SECTION 2222,
TITLE 13, OF THE CALIFORNIA ADMINISTRATIVE CODE



I.    INTRODUCTION

      MCD Associates, Inc. of 3 Harbor Road, Cold Spring Harbor, New York

11724, has requested an exemption from the prohibitions in Vehicle Code (¥.C.)
Section 27156 for the Model YW—34 turbocharger system manufactured by Legend

Turbo Inc. (LTI).    The LTI Model vw-34 turbocharger system is intended for

installation on 1984 and 1985 model—year Volkswagen Jetta, Rabbit and Scirocco

models equipped with 1.8 lTiter, fuel—injected engines.

      MCD Associates, Inc. submitted data from comparative (baseline vs.

turbocharged) emission tests conducted on a 1984 Volkswagen Jetta GLI

(49—state certified) equipped with a 1.8 liter, fuel—injected engine, at
International Automotive Testing Laboratories, Inc., Hilltown Industrial Park,

861 Cath—Scott Road, Telford, PA 18969.    Confirmatory tests were conducted on

a 1984 VW Scirocco (California certified) at a second independent laboratory

and also at the Air Resources Board (ARB) laboratory in E1 Monte, California.

II.   CONCLUSION

      Based on the submitted information and the results from comparative

exhaust emission tests performed at an independent laboratory on a 1984 Jetta

GLI, and from the confirmatory tests performed at a second independent

laboratory and at the ARB on a 1984 Volkswagen Scirocco, the staff concludes

that the Legend Turbo Inc.‘s Model YW—34 turbocharger system will not

adversely affect exhaust emissions from the specified vehicles.


III.      RECOMMENDATION

        The staff recommends that LTl be granted an exemption from the

prohibitions in V.C. Section 27156 for the company‘s Model VW—34 turbocharger

system for installation on 1984 and 1985 model—year Volkswagen Jetta, Rabbit,

and Scirocco models equipped with 1.8 liter, fuel—injected engines.      The staff

also recommends that Executive Order No. D—155 be issued.

IV.     LTI MODEL VW—34 TURBOCHARGER SYSTEM

        The assembly of the LTI Mode] VW—34 turbocharger system is shown in

Appendix A.     The major components of the system are:   exhaust manifold, a

turbine, and a compressor.     The original equipment manufacturers (OEM) exhaust

manifold is replaced by the LTI exhaust manifold.     The turbine inlet mounts

directly to the exhaust manifold.     The turbine, driven by exhaust gases, is

linked to the compressor by a solid drive shaft.     Intake air is routed from

the air flow meter (sensor) to the compressor through the compressor inlet

pipe.     It is then compressed and routed into the intake plenum through the

cross—over pipe.     Exhaust gas from the turbine is sent to the catalytic

converter via the exhaust downpipe.

        Lubrication and cooling of the turbocharger bearings is provided by a

fiber braided (special material impregnated) tube from a tap into the main oil

galley.     Lubricating oil from the turbocharger is returned to the oil pan.

        Maximum positive pressure (boost) is limited to 7 psi by a wastegate

internally mounted in the housing of the turbocharger.     The wastegate control

assembly rod is set during device installation so that the boost pressure

cannot exceed 7 psi.

        The heart of the LTI Model VW—34 turbocharger system is the Model RHBS2

turbocharger, manufactured by Ishikawajima—Harima Heavy Industries, Inc. (IHI)


     of Japan.    This is a radial turbine type turbocharger, having a throat area

     {A) of 696 sq. mm (1.08 sq. in.), with a distance (R) of 46.4 mm (1.83 in.)

     from the centroid of the throat area to the center of the vortex and an A/R of

     0.59.
             The compressor used for this application carries the designation NR BRL

     393 BZ.     Appendix A—1 shows the applicable compressor map with the full load

     vehicle acceleration line included.     This line is based upon the following:

     a) determination of the boost vs. rpm profile through experimental testing,

     and b) determination of the volumetric flow assuming an 85 percent engine
     volumetric efficiency through calculation.

             Boost is regulated with an integral wastegate controlled by a

     conventional pressure sensing actuator assembly.     Pressure build—up in the

     compressor outlet scroll acts on a diaphragm in the actuator assembly.

     Movement of the diaphragm, as a result of the applied pressure, is opposed by

     a calibrated spring.    When the force exerted by the pressure exceeds that

     exerted by the spring, the diaphragm defiects, moving the linkage rod and

     opening the wfistegate to relieve the pressure.     Appendix A—2 shows the Control

     Assembly for RHB52 in detail.

             An overboost protection feature has been incorporated into the OEM

     ignition system as shown in Appendix A—3.    A normally closed, pressure
‘t




     actuated electrical switch opens when manifold pressure exceeds 8.0 psi,

     disrupting the 12 volt supply to the positive side of the coil.     This

     de—energizes the ignition module which, in turn, de—energizes the fuel pump

     relay and fuel pump.    Both ignition and fuel delivery are interrupted thus,


boost levels drop.   This ignition system with overboost protection circuit is

functionally identical to the overboost protection mechanism used by Chrysler

Corporation on all their 1984 and 1985 model—year turbocharged vehicles.         The

system operates only when a mechanical failure results in manifold pressure

which is so excessive that severe engine damage is likely to occur.        The boost

versus rpm profile at full load was established on the dynamometer.        The

dynamometer test results are shown in Appendix A—4.

      Lubrication and cooling of the turbocharger bearings are effected by

circulation of oil drawn from a location on the oil filter housing originally

occupied by the "Yow engine oil pressure" warning light pressure switch.         The
switch is removed and a tee installed in its place.     The switch is relocated

to the vertical leg of the tee and the turbocharger oil supply line is

connected to the horizontal leg of the tee.    Oil drains out of the

turbocharger by gravity through a steel upper drain tube, a short rubber hose

and a steel lower drain tube into the oil pan.

      The OEM fue! induction system and intake manifold were kept intact; no

modifications were done to them.    Air, coming from the air flow sensor, is

routed directly to the throttle body in the OEM configuraton.     In the

turbocharger configuration, inlet air is redirected, filowing from the air flow

sensor exit to the turbocharger compressor inlet, through the compressor, and

then from the compressor outlet to the throttle body.    The air flow sensor

exit to compressor inlet tube and the compressor outiet plenum are shown in

Appendix A—5.

      The static ignition timing is retarded three (3) degrees during

turbocharger system installation.   Ignition timing at idle is, therefore,

changed from 6° BTDC to 3° BTDC.


      Turbocharger installation requires modification to the OEM exhaust

system between the exhaust parts and the catalyst inlet flange.     Three new

pieces are added:

      a)     Exhaust Manifold — It is modeled closely on the OEM manifold, only

the outlet was changed in order to provide an outlet flange compatible with

the turbocharger inlet filange.    Nodular iron, rather than gray iron, is used

because of its superior strength and resistance to high temperature.

      b)     Turbocharger OQutlet Elibow — As the turbocharger outiet flange is

extremely complex, the exhaust pipe cannot be mounted directly to the

turbocharger.    The cast outlet elbow (of nodular iron material) mates with thé

turbocharger and provides a viable exhaust pipe mounting flange.     The oxygen

sensor has been moved from the manifold to this elbow to avoid exposing the
sensor to high exhaust manifold temperatures under boost conditions.

      (c)    Exhaust Header Pipe — The exhaust header pipe runs from the outlet

eTbow to the catalyst inlet flange and incorporates a corrugated, flexible

section to absorb engine motion and vibration.

      The valve train, EGR system, and catalytic converter are kept

unchanged.   The OEM air fuel mixture feedback control in the closed—loop

operation is unaffected by turbocharger installation.     The turbocharged engine

requires that the system also operate open—loop at manifold pressures

exceeding 0.75 psi.    This is accomplished through the use of two (2) pressure

actuated electrical switches.     Switch #1 exposes pin #17 on the ECU to ground

when manifold pressure rises above 0.75 psi.     This causes the control system

to operate the frequency valve at a fixed duty—cycle of 80% which is

equivalent to the duty—cycle used in OEM open—loop mode.     Switch #2, actuated

at manifold pressures above 1.75 psi, drives the frequency valve to 100%


duty—cycle for improved performance and detonation suppression at high boost

levels.       Appendix A—6 shows the switch assembly in detail, including switch #3

used in the overboost protection circuit.

         The OEM positive crankcase ventilation {PCV) system is unchanged except
for the addition of the one—way check vaive.            This check valve is required to

avoid pressurizing the crankcase during periods of positive manifold pressure.

¥.       EMISSION TEST DATA

         A 1984 Volkswagen Jetta GLI (49—state certified) was used for testing by

the applicant.       A 1984 Volkswagen Scirocco (California certified) was used for

confirmatory testing.         The dynamometer equivalent inertia weight and road load

horsepower used were 2500 lbs. and 8.0 hp, respectively.

         The International Automotive Testing Laboratory (IATL) Inc. in Telford,

PA conducted a set of comparative CVS—75 emissions tests on the VW Jetta GLI

for the applicant.

         The Automated Custom Systems {ACS) Inc. in Anaheim, CA performed CVS—75

tests on the VW Scirocco in the turbocharged configuration.            The ARB conducted

confirmatory tests on the same vehicle at the Haagen—Smit Laboratory in El

Monte.       A summary of the test results is tabulated as follows:


                                    CVS—75 Test Results


                     1984 Volkswagen Jetta GLI (49—State Certified)

     ~Test             Test             Exhaust Emissions {gm/mi)         Fuel Economy
      Facility         Mode             HC        cCO          NOx           (mpg)
      IATL             Turbocharged     0.21      1.94         0.14          —=

      IATL             Baseline         0.25      3.39         0.06          ——


                   1984 Volkswagen Scirocco (California Certified)

      Test                 Test              Exhaust Emissions ({gm/mi)   Fuel Economy
      Facility             Mode              HC        cCO       Nox         {(mpg)
      ACS                  Turbocharged      0.18      1.81      0.24       21.95
      ARB                  Turbocharged      0.18      2.34      0.16       23.89

      1984 Yolkswagen Emission
      Certification Values                   0.21      1.60       0.10

      1984 California                        0.41      7.00       0.70
      Emission Standards

VI.     DISCUSSION

        A.    TEST VEHICLE

        The emission test results submitted by the MCD were obtained from a

49—state certified 1984 Yolkswagen (VW) Jetta GLI.

        The applicant claimed that the emission control systems performance of

the following two 1984/1985 Volkswagen engine families:

                     EVW     1.8   V6GFAF5   (49—state certified), and

                     EVW     1.8   V6FAC2    (California certifiéd),
is equivalent.      The applicant submitted comparative design data which show

that the only difference between the two engine families is the presence of an

air preheater unit, and an altitude compensated warm—up regulator on the

49—state vehicle/engine, while the California engine does not have these

components.      The staff verified the above information and requested the MCD to

deliver a California certified vehicle, a 1984 VW Scirocco, for confirmatory

testing.

       B.     EMISSIONS

       The applicant submitted comparative emission test data of the LTI Model

VW—34 turbocharger system.          The comparative CVS—75 test results from the 1984

Volkswagen Jetta GL1 included in the application package showed no significant


emission effects on the test vehicle with the turbocharger system installed.

The difference of 0.08 g/mi in Nox emissions of the comparative test data

between the baseline and turbocharged configuration is not considered to be

significant by the staff.

      Confirmatory CVS—75 emissions test data from the 1984 VW Scirocco showed

emission levels well below the current 1984 and subsequent model—year

California vehicle emission standards.
      C.    DURABILITY

            1.   Temperature Study

      The applicant conducted a dynamometer temperature test program to study

the change in exhaust temperatures due to the installation of the turbocharger.

Testing began with the engine in the stock, normally aspirated condition and

was completed after turbocharger installation.      Four major areas of operation

were examined:

                 a.      Part load, normally aspirated

                 b.      Full load, normally aspirated

                 c.      Part load, turbocharged

                 d.      Full load, turbocharged

      The exhaust temperature test results indicate that the heat generated by

the increased mass flow of fuel/air mixture in the turbocharged mode is

converted to mechanical energy in passing through the turbine.      The

temperature drop across the turbine resulted in lower catalyst inlet and

outlet temperatures.      However, these lowered temperatures do not result in

increased emissions as indicated by the emission test results.      Lower catalyst

inlet and outlet temperatuers also indicate that the open—loop fuel enrichment

calibration is operating properly and that the catalyst is functioning as

designed.


           2.    Mileage Accumulation

      The 1984 VW Jetta GLI was also used for durability study.     The applicant

used a road course for mileage accumulation.    This course was intended to

provide a means of accumulating mileage in a carefully monitored fashion, over

a route encompassing both city and highway miles, at an average speed similar

to that generated by the EPA‘s Durability Driving Schedule generally used in

formal mileage accumulation.     Four thousand (4000) miles were accumulated over

the route prior to back—to—back emission testing.    All mileage accumulation
was performed with the turbocharger system installed.     The subsequent

emissions test results indicate that the turbocharger system functioned well

after 4000 miles of operation.

      Although the 2nd test vehicle, the 1984 VW Scirocco, did not have

mileage accumulation with the turbocharger system installed before the

back—to—back test, it is expected that its performance with mileage

accumulation of 4000 miles would be very similar to that of the 1st test

vehicle, the 1984 VW Jetta.
      The staff reviewed the temperature curves submitted by the applicant and

found that the catalyst inlet temperatures of the turbocharged engine are

below those of the OEM engine.    Therefore, any possibility of substrate

meltdown or precious metal loss or migration from catalyst overheating are

eliminated and the durability of the catalyst is assured.

      D.   WARRANTY

      The applicant warrants the Legend Model YW—34 turbocharger system

(System), including any component parts installed with the System, against

defects in materials or workmanship for a period of tweive (12) months or

twelive thousand (12,000) miles (whichever occurs first) from the date or


mileage when the System is installed on a vehicle, provided that the System is

installed by an authorized LTI installer.         This Warranty does not cover

failures in the System which are the result of normal wear, accident, Acts of

God, unauthorized modifications to the System, or maintenance or use of the

vehicle or the System that is not in accordance with the manufacturer or by

LTI.     The Warranty extends to original and subsequent owners of the vehicle in

which the System is installed.

         E.      EVALUATION

         The applicant submitted a comprehensive application package including

comparative emissions test data, exhaust temperature study data, warranty

statement, installation/maintenance procedures, and packaging/identification

labels.       The applicant also provided a test vehicle for confirmatory emission

tests.        The staff evaluated the submitted information and the comparative

emission data and found that the LTI Model VW—34 turbocharger system will not

adversely affect exhaust emissions from the applicable vehicles and that the

turbocharger system is in compliance with the requirements for exemption from

the prohibitions in Vehicle Code Section 27156.




                                         — 10 —


APPENDICES




— 11 —


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                                                    APPENDIX A—3




                                   Wiring Diagram For Ignition System
                                   With Overboost Protection Circuit




           _L          {O                                               T             12 velts
           GND         fuel pump                                     fB]



(Irl,_            ignition
                  o   ——— fld\                                  fuel pump relay

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                  L            |

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                                   ignition soil‘           press switch              ignition module
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                                                  APPENDIX A—5




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Document Created: 2005-09-01 12:45:02
Document Modified: 2005-09-01 12:45:02

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