Let the tinkering continue.....

[Greg Roles]

how far down would you need it with the particulate filter? i'm only guessing here but wouldn't burning oil be a big no no for clog-unfriendly DPFs?

i love the way you rationalise your mods. it's not like "i'm lazy, i'm going to the ecs tuning webpage, i'm buying $20k worth of shiny plastic".

Thanks dude, but the fact I DON'T have an unlimited budget is part of it....but also the challenge in making the "few off the shelf options" model quick. Like to pioneer and be different.

[Greg Roles]

After a bit of searching, found the exact valve the mad polo guy used:
http://store.summitracing.com/egnsea...115+4294821958

Will visit my friendly bogan parts shop tomorrow!

[gldgti]

ok.... transporter has made a good point about plumbing it back into the intake...

i think with the provent doing its job, maybe the best option IS just to plumb it back into the air inlet. this atleast ensures that any more vapours will be burned.....


OOOOHHHHH! i just had an IDEA!

ok, so we dont want oil filling up the intake, but we dont want to put the oil into the air or into the exhaust...

what if we plumb the provent air into the intake AFTER the intercooler and EGR - like just before it goes into the manifold... with a 1-way valve, so that it only vents during times when there is manifold vacuum? BEFORE YOU FLAME ME - i often see a little vacuum in my inlet when engine braking, due to the turbo and intake creating a little pressure drop....

i guess the only problem with this idea is long periods of cruise... it might work ok around town though. ok.. so its not the best idea.... but its a thought...

[philthy]

Awesome find Phil, thankyou! I'm onto one of those valves!

My Provent plumbed currently to air is nasty. All I can smell is burning oil at the lights, and at night, I can see the smoke in the headlights if the breeze blows that way. I have a new Provent insert. The pipe is still oil drip free,and the Provent is collecting liquid well but there's a LOT of blowby gas in the GT TDI. I have to dump it in the exhaust far enought up that it will burn, as even plumbing it out the back, is going to give you, and the car behind, that sickly burning oil smell. It's not good.

The upside is my inlet is clean, even if I'm giving myself lung cancer.

No worries. Hope it works.

Plautos certainly isn't scared to tinker, I think he's done lots more to his car then most of the local boys.

[Transporter]

ok.... transporter has made a good point about plumbing it back into the intake...

i think with the provent doing its job, maybe the best option IS just to plumb it back into the air inlet. this atleast ensures that any more vapours will be burned.....


OOOOHHHHH! i just had an IDEA!

ok, so we dont want oil filling up the intake, but we dont want to put the oil into the air or into the exhaust...

what if we plumb the provent air into the intake AFTER the intercooler and EGR - like just before it goes into the manifold... with a 1-way valve, so that it only vents during times when there is manifold vacuum? BEFORE YOU FLAME ME - i often see a little vacuum in my inlet when engine braking, due to the turbo and intake creating a little pressure drop....

i guess the only problem with this idea is long periods of cruise... it might work ok around town though. ok.. so its not the best idea.... but its a thought...

Good idea gldgti ... worth of trying just be sure that the one way valve have the cracking (opening) pressure lower than max. allowed pressure in the crankcase, so the seals don't blow out.

I think that the original set up is the safest one for the engine, only if VW would make the oil separation better. That would be the area where I would start to tinker, if I had the time.

[Greg Roles]

Great points boys, but I'm in motion. I'll consider other ideas if this doesn't work, and there's only one way to find out. My end aim is nothing BUT intake air in my intake.

[gldgti]

Great points boys, but I'm in motion. I'll consider other ideas if this doesn't work, and there's only one way to find out. My end aim is nothing BUT intake air in my intake.

fair enough - just keep in mind one little thing - intake valve seat wear - you need a little oil in there to stop it!

[Greg Roles]

Mate that's clutching at straws.....but the turbo bearings are total loss remember....

[gldgti]

haha - no really - here's why i mention it.

back in the old days, when i wasnt born yet, the n/a 1.5 diesel engine had a nice intake with big long runners. the airbox, affixed above the rocker cover, had the breather pipe going right into it behind the filter. in the bottom of the airbox, on the casting side (part of the manifold) are the tops of the runners, just before they enter the head. and here, in the top of each runner, VW had drilled a 0.5mm hole, to allow oil to drip down and lubricate the intake valve seats.

now, i can't say that your engine "needs" this. nor can i say that in the 1.5 this actually worked properly (since a 0.5mm hole in the bottom of an airbox will fill up with crud pretty fast)

nonetheless, VW thought to bother to do it... so there

[Greg Roles]

OK, a long overdue update, but I'm afraid thanks to being made redundant in May, tinkering is going to be pretty quiet till I get some excess cashflow again! Living off my (limited) fat right now...

The upside is I can finish all the things I already have, and I'm busy learning about some new ideas out there that appeal to me, such as compound turbo's. All dreams till I get extra cash again!

What I do have is a Moroso crankcase ventillation set I won off e-bay USA, as it has proven difficult to get just the large bore one way valve locally they use to vent oil blowby gas into the exhaust pipe. As this system is designed for an 8, I ended up with a few excess parts, so if anyone wants to follow my lead, I have extra's. I can easily copy this to make a third. The whistle cut faces the exhaust flow, with the pipe entering at 45 degrees from the front, and is obvioulsy designed to cause venturi suction. The valves are very nice, and it's easy to work them by blowing into them, they open very easily in one direction, but are totally sealed in the other direction no matter how hard you try. I'll get them welded in asap, so I can stop smelling oil fumes at the lights. At least my inlet is staying clean!

[Transporter]

Greg you should take the pictures inside the inlet manifold and the tail pipe as well.
How many km's have you done so far in total?

Great install I'm jealous.

[gldgti]

great stuff mate. finally we see pics of someone chopping up a GT exhaust..... about time too

i would hazard a guess that you probably wont get any combustion in the exhaust from this mod - diesel exhaust is just too cool i reckon. if i see 600C pre-turbine, gosh its gotta be a fair bit cooler once it gets through the dpf and then to the venturi. then theres the oil vapour being so darned hard to ignite.

so am i right to think you now have absolutely no crancase gasses going back to your intake???

[Greg Roles]

Can't believe how much I've missed chopping stuff up, had a ball at the exhaust shop. Definately got the bug again, and it's full steam ahead on the weekend!

Yep, apart from the turbo bearings, there's no more oil vapour in my inlet. Interestingly having driven around for a few weeks at total loss, the outlet pipe was still clean, so all that is coming out is indeed vapour. The Provent is pulling out most of the oil itself, and I drained a good wack from it again last night. A Provent plumbed back into the inlet at the stock points is a must do mod for the TDI's.

I'd have to agree, that whilst this mod would work on a hotter petrol engine, I figure all I've really done is move my oil "smell" out my tailpipe. I can't "really" smell it, but it is hard to pick, and I'm not too keen on taking too many lungfull's of diesel exhaust. I figure I'd fail emissions though, so I need to clean it up a bit, just because I'm not keen on needless pollution.

I'm looking into putting it in higher, and if and when the DPF get's shelved, well it'll go way up high. Ways off that stage for now though.

Personally I wouldn't recommend this mod to anyone at this stage as I'm unsure of the success of it, but I'm going to persevere and optimise it as much as I can.

I measure 400-600 degrees after the DPF on Vag com, and up to 800 before it, but you're right in that normal driving is more like 100-300 after the DPF, and to effectively burn the oil vapour I feel you need much more heat.

In the end I want a custom tune, and there'll be plenty of heat if I have my way!

[jayjay]

i love all these little ingenious manifestations on your tdi!

i'm guessing the milltek/custom code DPF delete is going to end up somewhere in this car down the track?

good to see this updated

[CatonaPC©]

Cogdoc, you're just the man I've been looking for! I've got a Honda self-propelled that can use some midlife upgrade and a John Deere ride on with a Kohler 14.5hp engine that can use a bit of a lift too!

Can you bolt a turbo on the ride-on? The thought of doing donuts on the road after I've mowed the lawn intrigues me! (That won't break the hydrostatic transmission, will it?)