B5 Intercooler Leaking Oil

[Mike'A]

So can I assume that there is no cure and a periodic mop up is the cure?

[caldirun]

What is actually causing the problem, and can it be cured, is that too much to ask?

I think it is a problem with the crankcase breathing system the pipe comes off the lower side of the cam cover and enters the turbo intake. The air/oil vapour is compressed by the turbo compressor and heats up then is cooled as it travels around the pipework into the intercooler thus condensing the oil vapour leaving your annoying oil.
I have cleaned my system out very throughly and siliconed all the joints, it was great for a few thousand miles now it leaks. I am considering replacing the quadra seals on the intercooler pipes with o-rings as the flexing of the joint eventually breaks the silicone seal. If this works I will post the o-ring size.
I have not priced a new cam cover but I think it will be expensive, I wonder if the filter can be washed out with solvent, they are usually just a mesh of wire and tend to clog.

[passat 130 tdi]

would a few holes drilled into the breather pipe help ????

[caldirun]

would a few holes drilled into the breather pipe help ????

You would then lack crankcase ventillation, the vapour would find its way out, I once had a Triumph with blocked breather pipes, it blew oil up the dip stick hole, what a mess that made!

[passat 130 tdi]

guess the only other option then is some kind of catch can situated somewhere inline with the crankcase ventilation pipes.

[Frank.A]

In the USA many owner fit various forms of catch cans or oil seperators such as the Provent.Tests carried out in the US showed that the majority of the oil vapour which finds its way out of the breater is from the vacuum pump lubricating oil which exhausts into the rocker cover.Try a search for CCV or crankcase ventilation on forums such as TDI club.

http://forums.tdiclub.com/

Here's alink to the Provent website.

http://www.reitschle.com/MANN/Provent_Brochure.pdf

Best,
Frank

[Mike'A]

Thankyou one an all, I am begining to understand the problem now. A catch can would seem to be the answer. I was agitated by the mess, now that I am more aware and the fact that my Passat is coming close to five years old and this is just showing I suppose that I'll start mopping up, only 37000 miles though!

Thanks Mike

[Mike McKinstry]

Am I right in thinking the front has to be put into "lock mode" with bumper off etc to remove the i/cooler or has anyone got i/cooler out just with bumper off or just undertray?

Mike

[Mike McKinstry]

Also,if I am going to take intercooler out can anyone advise me what I should require or replace on reassembly so i can get parts ready.Would presume new o rings ,what about grommets etc?

Mike

[passat 130 tdi]

right hand intercooler pop rivited on ( 2 i think top and bottom ) then it simply pulls off its rubber mounts , no o rings just the black hose that slots in , chances are your intercooler is simply swimming with old oil when you take off the hose to it. you may be lucky and get it out with the passenger side of the bumper undone , taking off the whole bumper is pretty easy like , takes about 20 minutes to remove fully.

if time is not an issue how about simply filling the intercooler with petrol or derv and let it run out to clean inside , or would this too long ???