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Old 01-13-2012, 10:02 AM   #25 (permalink)
Josh8loop
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Join Date: Aug 2011
Location: Port St. Lucie, Florida
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Quote:
Originally Posted by RH77 View Post
I understand your concerns regarding the PCV system, but I have a few follow-up questions, statements, and a respectful difference of opinion in some situations...

In the case of Josh8loop's TDI, it appears that a reasonable collection system was designed to remove a nominal amount of oil from the turbo bearing seal and then from the crankcase. If a pressure guage were to be applied to the capillary tube, I expect a very small reading of negligible, intermittent pressure. I would imagine that losing small amount of oil is typical for a turbo, with the speed, temperature, and pressure of the application? Also, turbochargers in consumer applications tend to fail at the 100K mile mark (on the average) without proper cooldown during the life of the component. Timed idling before shutdown (not advised for FE) or light driving before shutdown, has demonstrated a preservation approach to turbo longevity, as you probably know.

To demonstrate the amount of emissions from this system on a larger scale, take a look at a large, rear-engined tour bus. Since a closed PCV system is not required for large vehicle applications, a vent tube generally exhausts the vent directly into the atmosphere. If one looks underneath while the vehicle is at idle, the downward-pointed tube is often clearly visible, and vents quite a bit of contaminants. If left stationary and idle for a while, a greasy/oily spot can be seen on the pavement where this tube vents.

These vehicles are designed to run 100's of thousands of miles, and typically vent a considerable amount when relatively new. Would diesel engines have more blow-by due to the higher compression and a larger supply of oil? In our small, closed PCV systems, we simply want to condense and collect the discharge before it can potentially degrade downstream components or senselessly be burned and released into our air.

My personal goal (and likelly that of others) is to remove airborne pollutants, contaminants, and whatever blow-by occurs in normal engine operation -- and especially as engines accumulate more hours and inevitably wear out their piston rings. The system has existed for a reason (for decades), and can account for significant air quality issues if not maintained. For those strapped for cash, it can be an inexpensive addition to prevent costly and inefficient operation later.

Further, despite the closed nature of the sytem, I would expect condensation and warm-up evaporation to be a factor on cold starts and/or humid days, increasing the vapor amount.

I applaud Josh's collection of intercooler contaminants, through carefully constructing a relatively non-invasive setup. Whether or not the turbo is significantly leaking, collecting over 5 oz. of comtanimants over 50K miles establishes the "every little bit helps" rule, and thus far, has not been reported to be a detriment.

As for me, I plan to continue my usual maintenance routine, involving the use of high-quality oil / filter changes, Seafoam cleanse directly into the intake, and the catch can. So far, 50K miles later, it sill runs smoothly and efficiently at 160K total miles.

RH77


Thanks for the kind words. This system I have adapted is similar to what the LandRover Diesel guys have installed as factory equipment on their vehicles with one exception. I added the lower IC bleed to somewhat passively address the lower IC buildup of oil which is perfectly normal for these vehicles. So the technology is not new, and I cannot take credit for it-I've just massaged it to meet my needs on this particular vehicle.

I'm not sure exactly what the comparison would be from an equivalent displacement of a gasoline engine and a diesel engine in terms of CCV flow. My guess would be that the diesel(due to higher compression) would have more. I know that if the diesel engine is equipped with a mechanical vacuum pump which vents into the crankcase then that does increase total CCV flow.

As you mention condensation can become an issue and to prevent that my design goal was to use short direct runs of piping to keep the CCV gasses hot so I don't drop out the water vapor and leave it in vapor form. I live in Florida, so I have more flexibility in this aspect. Others that are in the colder climates would want to keep things short, direct, insulated, and close to engine heat radiating components(just like BMW did on the X5 engine with this separator) to ensure little or no water vapor condensation happens.


I also use high quality oils to help keep the engine component life maximized, especially since I am running my "Hybrid" 205 Deg F thermostat. My car was designed for 195 F operation, and so I had to fabricate my own thermostat for it. So far 3-4 MPG increase from the higher temps, and from recent lower and upper end inspection no adverse effects have been noted.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 45 MPG City with the 01M, 5-speed 60+ MPG City. Nokian Entyre Low RR Tires. Experimenting with the "Hybrid" 205 Deg F T-stat:

http://forums.tdiclub.com/showthread...=306799&page=4

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Last edited by Josh8loop; 01-22-2012 at 09:29 AM..
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