Replacing the intake...any good ideas?

[Mikeyworks]

I was thinking of longer term projects on the Caddy (after the knock is resolved).  I was thinking of redoing the intake and possibly move it to a cooler place.

Does anybody have any ideas of what to do with it?

Also, any thoughts of that to do with the CCV tubes?  Just catch can them?  Any ingenious thoughts there?



Thanks,
Mikey

[VWRacer]

Mikey,

I eliminated the EGR and routed the crankcase vent to a catch can. You wouldn't believe the oily gunk that it was dumping into the turbo. Yuck! :shock:

Stan

[Dr. Diesel]

DON'T put it in the raintray.  WAAAAAAYYYYY too loud!
my testing indicates that the factory setup with paper filter is the best. just keep the filter fresh. I found K&N's do a ***ty job filtering. there was always grit in the inlet pipe.

[fspGTD]

Dr. D - the factory filter element is overly restrictive.  Try removing it, latching the airbox shut and testing with no element at all.  See if you notice a difference...  I'll bet you would.  The A2 1.6lTD uses the same air filter element as the A1 1.6lTD, I'm pretty sure.

I am VERY happy with the PRM air filter setup I've got on there right now.  Highly recommended...  more about it on this old hostboard topic.
http://www.hostboard.com/cgi-bin/ultimatebb.cgi?ubb=get_topic&f=4037&t=291

It dyno tested to be no more restrictive that a smooth-radius horn rampipe with no filter element at all.

[Mikeyworks]

Jake,

Nice setup. I remember seeing that a while a go on the other board. That's pretty sweet. Right now I have a pipercross cone and I am going to either fab a new intake pipe from f-glass or some metal (custom weld).

As for the EGR line, I will likely fab up a catch can for that....

As for the other line leading to the intake tube, what do I do with that? (you know, the one behind the EGR tube).

Mikey

[fspGTD]

Mikey - you don't have EGR.  (That's exhaust gas recirculation.)  You've got a crankcase vent which is where blowby vapors get recycled into the intake.

Let me show you what I did on my setup:


What I did on my crankcase vent was plug the hole in the intake tube using a 3/4" (or so?) plastic pcv-type (and by pcv here, I mean the kind of plastic used in the hardware store for plumbing supply fittings ) plug.  It's a little bit blocked by the boost tube in the above picture, but you can just see the end of the white plastic plug that I am talking about.  It fit in there just about perfectly.  Before that I had a synthetic wine cork in there which worked but is a little goofy.  The hard plastic plug is better because is gives something positive for the hose clamp to tighten again.

For the crankcase outlet on the head, I kept the stock rubber valve cover gasket and found a generic 90 degree plastic fitting that fit perfectly from an auto-parts supply store, it was packaged as some sort of PCV type (by pcv here I mean a fitting which was marketed for positive-crankcase-ventilation application sold in an auto part store )fitting but it didn't have any valve or restriction inside.  I connected to that some hose that just runs down the firewall behind the steering rack and vents vapors down below.  No catch can.  Very quick and dirty, an improvement would be some sort of filter that caught the oil vapors better.  The vapors are kind of nasty, but it's something that looks worse than it really is - IE the quantity of oil actually lost through the blowby vapors is nominal.  There can be quite a bit of blowby gasses at high RPM I've found!  At an autocross last sunday I pegged the revv limiter in 2nd gear and held that through a couple straight stretches on the course, essentially leaving the engine floored in 2nd gear on the revv limiter for seconds.  When I got done with my run, found the o-ring seal on the base of my dipstick had been pushed up around the dipstick tube from the excessive pressure, and a little oil came out around there as well.  This shows how much blowby vapors need to get out of there in those conditions!  By the way my engine is in sound shape, but it's just stock rings (not gapless total seal or anything.)  Noticed that the later model diesels (for example: 1.9lTD) have an extra crankcase vent on the side of the block where the fuel pump is on a carb-gas rabbit.  I might need to add a second crankcase vent at that location to help ease the crankcase pressures at high rpms.  This is a problem even on gas vw engines and they don't have close to the in-cylinder pressures we've got on our 23:1, boosted turbo diesels at high rpm.

The other line behind it is the blow off valve outlet.  I'd advise to just leave it.  Notice the blow off valve has a screwdriver adjustment to change the pressure it blows at, in case you need to use it.    It can be adjusted up to about 14+psi, I found.  You can add spacers underneath the adjuster to increase that range or even make it permanently closed if you want.

[type53b_gtd]

I ran with an open to atmosphere vent for a while, and the vapours were just too nasty for my liking.

I now vent the bottom end with an AAZ vent pipe the adaptor for which bolts right to the "fuel pump" cover on the side of the block.  This goes to an AAZ CCV pressure valve at the valve cover - which is in turn vented to the stock intake location.  Running the crankcase vent without a restrictor-style (read windage tray) oil pan gasket resulted in excessive oil vapour in the blowby at high rpms.  The windage tray helped with that, but I also stuffed some stainless scouring pad material into the top and bottom of the crankcase vent pipe to help trap oil vapours.

The AAZ has a  more effective oil trap incorporated in the valve cover - someday I hope to be able to take advantage of this.  The AHU TDI engine has a really cool oil trap which is available as a separate part, but I don't think it can be retrofitted to either the AAZ or the 1.6 valve covers.

Drew

[Mikeyworks]

Hey gang,

Thanks as always. I learn something new here every day!!!!

I will have to play with the intake, but the first thing is to replace the crank bearings...see my other thread.

Thanks again,
Mikey

[stewardc]

Was there ever any progress made on this item? I'm planning on replacing the really ugly valve cover breather with something "prettier", but would like ideas first.

[Mikeyworks]

No progress really on my end as I got the truck up and running and then put a softball sized hole in the side of the engine...almost a year ago.

I am now toying around with my 2000 Jetta TDI with 317K on the clock!!!

It's fun, but I miss my old Caddy.

[BlackTieTD]

your's wouldn't be the first TDI caddy!! do it

[Mikeyworks]

Oh I would have....but the wife would have nothing of it.  I sold the body of the Caddy last fall.  :-(  

I considered the swap, but decided to just keep the Jetta.

Mikey

[hillfolk'r]

onmy old 84 jetta td,,iremoved the airbox,and shoved a 3 inchpipe in the hose and  hooked up a cone k+n,,and built a better box around that so it would draw fresh air,,,,i found some cool stuff made by CRC its called "corrosion shield",,i sprayed the inside of the steel pipe with it,soit wouldnt rust,and traps some dust too,,its like cosmoline,,,avoid cheap rice cone filters,ive got 2 or 3 and if i got a k+n off the bat iwoulda paid once,,,the cheap ones dont use stainless wire mesh,,it RUSTS,,wanna suck in rust??get a good filter,,,ihad it drawing the intake up in the raintray in my old truck,,it wasnt loud,,the open downpipe was loud,,,the intake noise isnt gonna be that bad,,,my tdi has a loud intake noise,,way louder than a idi

[GTD.]

Nice charge pipework

What I did on my crankcase vent was plug the hole in the intake tube using a 3/4" (or so?) plastic pcv-type (and by pcv here, I mean the kind of plastic used in the hardware store for plumbing supply fittings ) plug.

I think you mean PVC (Poly Vinyl Chloride)

[hillfolk'r]

OH NO,,DONT JUST PLUG THE PCV HOSE,DOWHAT IDID,,PUT IN Aoops caps,im sorry,,,put in a water injector setup,thats what idid with the open hose,,2 fer 1