Provent Instalation 2.0 PD TDI

[InMused]

After discussions with Cogdoc and reading though a mountain of posts I have decided to have a hack at installing a Provent on my Jetta. I have not been able to find pictures or instructions for my specific engine so I though I might document my questions/answers and installation here.

I am looking at this kit from Western Filters (thanks Roaming Refuge) as it comes with additional installation hardware:

• 1x provent 200 crankcase unit
• 2x 1mtr lengths of 5/8" silicone oil resistant hose
• 1x 1mtr length of 3/4" silicone oil resistant hose (may not be required for patrol users)
• 1x 1ft lentgth of 1" silicone oil resistant hose
• 2x reducing straight joiners from 1" - 3/4" & 5/8"
• 8x stainless hose clamps.

I also found this how-to that positions the Provent on the oil filter housing. See below:



While this is not my engine (and there is no room next to my oil filter) I started looking towards the front of the engine bay. Is there any reason (size, heat, movement etc) that would prevent me from locating the Provent on the fuel filter housing utalising the void between the fuel filter and the headlamp? See below:



I have been looking at hose routing and thought that I could rout the hoses accross the top of the engine to the top left corner and along the void between the pulley housing (I hope that's what it is) and the coolant expansion bottle to the Provent mounted on the fuel filter housing. I can't see any problem with regards tot he engine cover. My questions are, is there any heat issues with running the EGR line so close the coolant system?



I assume (noob question) that the flow that I am bypassing flows in the direction of the arrow?



I haven't thought about the drain yet.

Anything else I need to be aware of?

Cheers in advance. Pax

[Transporter]

I don't think that there would be enough room next to the fuel filter, Greg Roles installed it next to the battery and further down back.
You've got it for a good price since it comes with the hoses.

[Greg Roles]

The idea is a good one, but as it's actually slightly bigger than the fuel filter cannister, it's a tricky beast to fit anywhere!
The hose routing is fine, but you will find silicon hose won't do those sort of bends without kinking, and joiners / elbows only reduce overall flow. Use as few as possible, I ended up with none.
Yep that flow direction is right, and it's great to see a kit out there with the right sort of hose.

When it arrives you'll see what I mean about the size, and it's only the baby one in the Provent range, you should see the truck ones!!

[InMused]

The idea is a good one, but as it's actually slightly bigger than the fuel filter cannister, it's a tricky beast to fit anywhere!
The hose routing is fine, but you will find silicon hose won't do those sort of bends without kinking, and joiners / elbows only reduce overall flow. Use as few as possible, I ended up with none.
Yep that flow direction is right, and it's great to see a kit out there with the right sort of hose.

When it arrives you'll see what I mean about the size, and it's only the baby one in the Provent range, you should see the truck ones!!

Thanks Greg and Transporter, you must have your computers in your tinker garage.

It is bigger than I thought. I pulled the specs and found a household item the same size - a 400g Milo tin. Your right, it doesn't fit. Maybe this is why VW doesn't install a oil/air separator as stock; they can't fut it anywhere either.

Is there any reason why the Provent 200 is prefered over the 150. The 150 can be used with engines up to 200Kw and is 20mm small in its housing diameter?

I am keen to have it located in a spot that makes it easy for future servicing. If only the air box wasn't such a space hog. Hmmmm. If I install a pod filter I would have enough room up front in front of the battery box in a serviceable position maybe?

Could copper tube be used and bent into an appropriate shape?

I assume there is no way easy way to flip the EGR vent outlet around so that it faces right?



PS. You guys a champs. I have learned so much in the last few days.

[InMused]

Did some more hunting around VWW and found mikinoz's Modshack intake thread. While I am aware that it will not provide me with Kw benefits, the space saved I think would be worth while for a simple install of the Provent.



Losts of space here and some mounting points to boot.

[Transporter]

Just cross fingers that it is deep enough. But instead buying a filter you could get the Optima battery (it is smaller) and you have the ideal space and location for the Provent.
Look at the Greg's engine bay around the battery. (maybe he can take a better picture of that location)

[InMused]

Just cross fingers that it is deep enough. But instead buying a filter you could get the Optima battery (it is smaller) and you have the ideal space and location for the Provent.
Look at the Greg's engine bay around the battery. (maybe he can take a better picture of that location)

Ok, looked into this and your right, its quite a viable idea. I had a look at Greg's engine bay and looked up Optima batteries. I need to have a look at the Battery area in my car a bit closer to see if i can fit both inside the battery case (or at least hide them under it.

I am going to build a model of each so that I can get a visual on the sizes.

[Transporter]

Ok, looked into this and your right, its quite a viable idea. I had a look at Greg's engine bay and looked up Optima batteries. I need to have a look at the Battery area in my car a bit closer to see if i can fit both inside the battery case (or at least hide them under it.

I am going to build a model of each so that I can get a visual on the sizes.

Just make sure that you get right capacity battery. Too small and it will not last very long. Grag's battery is about the right size.

[Greg Roles]

The reason to try and fit the 200 is flow. The sheer amount of blowby gas from a high compression diesel is immense, and you don't want to block that flow path in any way. Blocking it a bit, say with smaller than optimal hose will lead to a little extra oil loss as you end up with increased crankcase pressure, and even worse that is detrimental to power production! Eeek!! The 200 has the same 25mm sized ports as the VW has, so I stuck with it. The 150 has 20mm, and flows a max of 150mL a min, whereas the 200 flows a max of 200mL. I guess that's where the name comes from? I need to measure the actual flow rates to be sure, something I just might do oneday!

I was concerned about it so I plumbed my Provent without any elbows using 25mm silicon hose, despite the fact elbows would make it a lot nicer, and would certainly be easier! Very early on I put a piece of pot scourer steel wool stuff into the stock blowby pipe to try and condense the blowby, and managed to force a heap of oil out through the turbo bearings, the flow is just that great, certainly suprised me and this isn't the first crankcase system I've messed with, but the first diesel.

I'd suggest if you must, the battery is a better idea than the pod, unless you are performance orientated. Cost about the same, but the battery I got is smaller than stock, packs more power, and does allow the Provent to fit on the stock battery tray. Might not quite fit in the nice plastic box, but it'd be close! That would be a nice neat install, and if you don't plan to run a massive stereo like me, you can save $100 or so on the Oddessy by getting a Deka Intimidator ( not the Sport like my motorbike sized one ) gel battery, not sure on the dimensions though. I got mine through batteries direct from memory, but the online retailers have great prices. Have a search, they ain't cheap in the first place.

Not sure on the flipping of the tappet cover outlet, but I'd figure it's well and truely sealed on, given the pressure. You'll have to jig up a 25mm U bend out of copper pipe, I have a nice bead roller if you need to borrow it : )

I have been promising to look into a specific Provent fitment kit for the various TDI for some time now, and this is still something I aim to do, it's down to trying to find nice secure fittings to clip onto the stock outlet and inlet points, which is proving difficult, but I WILL get onto it over the coming weeks, there's a lot of PM requests!!! Don't wait for me though, too many projects right now, bit time poor!

[Madhatter_jc]

Well, my two Provents came today So the Skoda is getting one and so is the Tiguan.

Melbourne is kindly obliging and has provided a crappy weekend so "its to wet to do anything in the garden honey"

ohh yeah