Club Touareg Forum banner
1 - 2 of 2 Posts

·
Registered
2013 Touareg R line V8 Diesel
Joined
·
395 Posts
Discussion Starter · #1 · (Edited)
No one appears to have done this installation, so I thought I would record in this thread my approach as I do the work over the next few weeks / months.

Background

My 2013 R-line V8 TDI has now done 90k kms with 30k km being done in the last 2 years since I purchased it. In its previous life it was owned by the wife of a VW dealer in NSW and did few miles each year but had a regular yearly service at the dealership and I am sure it got the best possible attention when serviced.

Inspecting the inlet manifolds with a borescope showed a lot of oily carbon build up especially where the EGR enters just after the inlet throttles but less further down the manifold. As usual cleaning with the inlet cleaner spray cans only removed a little

Around 3 mm of build up around the EGR inlet which is the hole at the bottom about 70mm into the inlet.

There are currently no issues from the observed build up but I want to control it as I plan to keep the car for the long term and at least another 200k kms

Liquid Eye Flash photography Fluid Automotive tire



Less build up further down the inlet and cleaned better with the spray especially on the bottom

Grey Automotive tire Wood Gas Auto part




Planned Installation and long term maintenance.

My plans are as follows to keep the inlet acceptably clean long term

1. Install two Provent 150 catch cans. One for each inlet as the PCV vent splits to feed each inlet. I have these on order now. I looked at Provent 100, 150 and 200 and Ryco and Flashlube catch cans and using 2 of the Provent 150's appeared to be the right capacity ( rated to 200kw each) and the dimensions appeared best for the planned installation ( more details below)

2. Scrape out the first upper section of the inlet to remove the build up. This is easily accessible by removing the inlet throttle butterflies

3. Use the inlet cleaner routinely at each yearly service with a can for each inlet as a preventative to help minimise future build up.

4. Accessing the second lower section of the manifold for cleaning is much harder as it requires degassing of the AC system and removal of piping from the compressor and removal of HP fuel piping so the upper section can be removed . I am also not sure how badly fouled the lower section is and I will inspect more with the borescope around the bend once I get the upper section clean so the borescope lens does not get all fouled up. Hopefully this will not be required with the above actions

Details of planned Provent installation

There is not a lot of room in the engine bay for catch cans on the V8 TDI. It is also made more complex by the EGR system being buried under the inlet manifold and the EGR gases emerging out the front under the manifold in alloy hard piping that then splits and winds it way around the drive belt and engine ancillaries to each side of the engine to the intakes from the filters to the turbos

Looking down at the front of the engine you can see the alloy EGR pipe that runs to the RH inlet. a similar one runs to the LH inlet after the pipe splits just under the inlet manifold in the centre of the V next to the aircon compressor

Motor vehicle Automotive tire Light Black Automotive design



There is a short section of rubber pipe from the end of these alloy lines to the inlets. My plan is to cut the rubber line and run rubber line extensions to the catch cans and back to the inlets.

I plan to fit the Provent 150 catch cans on a bracket just in front of strut towers on each side of the engine. This appears to be the best place as there is enough room to fit the cans and the extra piping length will be minimal and access to the can top for filter replacement is good and the can drain line and valve can be run down to under the engine easily. Space on the RH side is more constricted than the LH due to the brake booster and brake lines but I think it will fit. I will confirm when I get Provent 150's delivered and post some more photos

to be continued

cheers
Rohan
 

·
Registered
2013 Touareg R line V8 Diesel
Joined
·
395 Posts
Discussion Starter · #2 ·
Some more photos on the installation challenges and plans

Below you can see the alloy PCV breather pipe emerging from under the inlet manifold next to the AC compressor and running under the compressor pulley across to the RH intake. You can also see the work involved to pull off the upper allow inlet manifold to get to the lower plastic manifold with the AC pipe and HP fuel pipe and electrical lines across the top of it.
Motor vehicle Car Auto part Automotive design Gas



Below the LH breather pipe and its rubber hose extension that runs from under the manifold to the LH intake
Motor vehicle Automotive fuel system Automotive exterior Automotive tire Auto part



The alloy pipes are 16 mm OD where the nominal 16mm ID rubber hose extensions connect. The Provent 150 catch can has 20 mm OD connections for nominal 19mm ID rubber hose so I will extend these 16mm ID rubber lines and get some 16mm to 19 mm adapters to connect to the catch can




Below is location for the RH catch can. I will fit it in front of the fuel filter and I will make a bracket that comes of the fuel filter brackets and bolts. The space is tight between the filter and brake lines and air cleaner but I think there is enough.




Automotive fuel system Motor vehicle Hood Automotive design Automotive exterior


LH side catch can installation has more space and I will make up a bracket to come off the strut tower bolts

Automotive tire Motor vehicle Automotive lighting Automotive design Automotive exterior


Just waiting now for the catch cans to be delivered so I can measure and make the brackets

Below a few general views of the 4.2l V8 TDI engine for those not familiar with it, not much room left in the Tregs engine bay.

Car Vehicle Motor vehicle Automotive design Automotive fuel system


Motor vehicle Vehicle Hood Car Automotive design


Automotive fuel system Motor vehicle Automotive air manifold Hood Vehicle



cheers
Rohan
 

Attachments

1 - 2 of 2 Posts
Top