The mk3 1.9L TD power-quest

[Greg Roles]

My man, the current TDI has no less than 5 oil seperation systems, including a cyclic of amazing design, and the whole thing takes up several pages in the study manual. It amazed me with it's complexity, and yet my provent is collecting a suprising amount of oil. In the first 9000k, with new car tolerances I've collected a few hundred mL. Certainly a lot more than you would like to have going through your intake, especially when it combines with the EGR circuit and mixes to make sludge.

My bet is this is the majority of your delimma.

[gldgti]

My man, the current TDI has no less than 5 oil seperation systems, including a cyclic of amazing design, and the whole thing takes up several pages in the study manual. It amazed me with it's complexity, and yet my provent is collecting a suprising amount of oil. In the first 9000k, with new car tolerances I've collected a few hundred mL. Certainly a lot more than you would like to have going through your intake, especially when it combines with the EGR circuit and mixes to make sludge.

My bet is this is the majority of your delimma.

well you convinced me.... what did you buy to fix it?

[Greg Roles]

I bought a Provent oil catch system from Mann and Hummell ( Aust ) in Sydney. It was rather dear at $200 plus post, but a very nice unit, and well designed. I'm sure a simple oil catch can, sealed, and reconnected into the inlet vacuum would be just as good, but at the time I had been messing with a few half arsed designs and got sick of oil everywhere so just bought it despite the hefty price tag.

Post #2.

http://www.vwwatercooled.org.au/newf...ad.php?t=13929

Here's how to make one from the awesome website Autospeed. I figure that's the ticket for you Mr Tinkerer !

http://www.autospeed.com.au/cms/A_1576/article.html

[smithy010]

That one on the autospeed website should be a doddle for you Aydan!

It's very nice.

[gldgti]

i smell an after work project coming on....

[Greg Roles]

Before you get too weld happy, I noticed supercheap have Monza ( chinese ) oil catch cans for $59. I've had one of these before, and they are pretty crude, but a reasonable starting point. I put some pot scourers in mine!

[gldgti]

meh - i can knock one up at work for little money and have it work perfectly.... might as well, then i can say its mine.

[gldgti]

well, a little update,
took apart the old intercooler piping setup in order to optimse it a bit, and get rid of 2 very tight rubber hose bends - and i came up with this....



also, i de-EGR'd the car. after taking off the cast alloy fitting that bolts onto the top of the intake manifold in order to inspect it, i was disgusted to find an enormous buildup of black goo - consisting of exhaust carbon and oil mixed together. i belive this is a trait of the early EGR setups which works very well to gum up your intake manifold.

i made up 2 blanking plates - one for the exhaust mani, and one for the inlet, and then just removed the rest.

i figure that hte exhaust blanking plate will be perfect for mounting a EGT sender, and the inlet one might be good for inlet air temp.

i also found that the intake manifold is grossly goo'd up aswell, but until i pull the turbo off, i cant get to the intake manifold bolts. therefore, it will have to wait - goodness knows how much power and efficiency is lost with all of that goo in there!

cant wait to pull the turbo and clean all that goo out now!

[Preen59]

Looking good dude. Sounds like you're making progress. Good stuff!

[Mischa]

updatesss?