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  #21  
Old 04-21-2015, 10:11 AM
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So sorry - Once again, the pictures are not working. I will work on getting the pictures added correctly.


Edit - pics hopefully working now.
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2010 e70 35d- now driven by son #2
2005 e53 3.0 - now driven by son #1
2021 G05 45e PHEV - now driven by me
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Last edited by sgrice; 04-21-2015 at 10:58 AM.
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  #22  
Old 04-21-2015, 10:25 AM
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The past is present (or is it future).

I am just now replacing my trusty 2003 TDI with an 35d E70 and remember closely following this thread at Fred's TDIclub.com. My ultimate cure for oil in the inter-cooler was to run and monitor oil level at minimum spec - about 150,000 miles ago.

Another thing we did in the area was to minimize the EGR duty cycle in ECU software. I replaced the TDI intake manifold at ~80k miles due to coking. My guru mechanic kept a stock of salvaged and clean IM and swapped it in less than an hour.
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  #23  
Old 04-21-2015, 08:26 PM
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Quote:
Originally Posted by sgrice View Post
So sorry - Once again, the pictures are not working. I will work on getting the pictures added correctly.


Edit - pics hopefully working now.
Great job! Just one question, does your d use any oil?
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  #24  
Old 04-21-2015, 09:18 PM
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This is fascinating stuff guys. I just bought an e70 x5 and I'm reading up on the coke/ tar issues.
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  #25  
Old 04-21-2015, 09:21 PM
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Quote:
Originally Posted by ZetaTre View Post
The original design was not effective enough so, as some may have read on the other board, I actually went ahead and installed a Mann+Hummel ProVent 200 separator.

I now have about 15,000 miles on the setup and I'm extremely pleased with the results. The oil in the intake has completely disappeared and the oil level in the sump has not declined.

I went through a few iteration and testing to ensure that the crankcase would not pressurize under any driving conditions. I have also modified the dipstick tube to make it the return line for the filtered oil and make the system completely closed loop.

I'm now refining the design of the takeoff plate: someone I know was able to scan the profile of the original CCV and machine the plate on CNC machine for a perfect design. I also found an aluminum elbow and I'll have it TIG weld to the plate for a clean and professional design. The plate currently mounted on the car is the proof of concept I made from a 1/4" aluminum plate cut to shape using a jig saw and soldering a copper elbow: it works but it's not pretty and the solder is fragile and I already broke it once while replacing the hose.

Also the hoses I originally used for the long term testing was a duct made of thermoplastic rubber: it turned out that it is either too porous or not resistant to the oil because the one running from the valve cover to the filter (which carries unfiltered fumes) have developed a film of oil on the outside. I went back to the Gates rubber hoses I had originally but have identified some corrugated nylon conduits that I may try if the rubber hoses don't work.

Some of the key takeaways of the project:

REROUTING THE BRAKE BOOSTER LINE

This was necessary to make enough room for the Provent



MAKING THE BRACKET TO SUPPORT THE PROVENT

Now that the brake booster line is out of the way I removed the bracket that was holding it...



and used it as a template to make a bracket that would go in the same location to hold the ProVent 200



See if it fits...



And install the ProVent 200...

What other board was this posted on?
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  #26  
Old 04-22-2015, 08:13 AM
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Split71 - I would say my 35d does not use an unusual amount of oil. I'm usually down about a quart when an oil change is due. For me, that's been about a quart every 10-12,000 miles. So (just as for ZetaTre) the reason to think about doing this is not because of oil usage, but because of trying to limit carbon build up.

Dalecan - ZetaTre originally made a series of posts over on bimmerfest. As you will see, he uses the ID of lpcapital over there. His first post (the link is here) is titled "Rather simple idea to reduce oil passing through crankcase?" Then a few months later he made a second post (the link is here) that is titled "Improving on a "Rather simple idea (aka Version 2.0)." He summarized those two posts into the beginning of this post. Though the post here covers the highlights, it is very interesting to read the original posts and see how things evolved over time, with obviously a lot of thought and effort going into it.
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2021 G05 45e PHEV - now driven by me
2008 ML320 CDI - driven by wife
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  #27  
Old 04-22-2015, 10:16 AM
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Quote:
Originally Posted by sgrice View Post
Split71 - I would say my 35d does not use an unusual amount of oil. I'm usually down about a quart when an oil change is due. For me, that's been about a quart every 10-12,000 miles. So (just as for ZetaTre) the reason to think about doing this is not because of oil usage, but because of trying to limit carbon build up.

Dalecan - ZetaTre originally made a series of posts over on bimmerfest. As you will see, he uses the ID of lpcapital over there. His first post (the link is here) is titled "Rather simple idea to reduce oil passing through crankcase?" Then a few months later he made a second post (the link is here) that is titled "Improving on a "Rather simple idea (aka Version 2.0)." He summarized those two posts into the beginning of this post. Though the post here covers the highlights, it is very interesting to read the original posts and see how things evolved over time, with obviously a lot of thought and effort going into it.
Thanks
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  #28  
Old 04-22-2015, 11:49 AM
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Wow! nice work sgrice!! Yes for sure its gonna help CBU problem.I will be doing in couple of months as soon as my CPO warranty expires.I had provent installed in my VW TDI and i removed it before selling.It really helped and my TDI's intake was clean and oil free.
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  #29  
Old 04-22-2015, 12:42 PM
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Great job budd!!!!

I REALLY like the hose you're using. I'm currently using some rubber coolant hoses but I may end up replacing them with what you bought. Let me know if they are working out fine!

Also, did you do the draining back through the oil dipstick? It can be a PITA to get the lower bolt...

Congrats!!!
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  #30  
Old 04-22-2015, 12:53 PM
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One thing worth mentioning: the reason why I actually removed the sound proofing material is because it collects and soaks up with water. This causes corrosion around injector #5. To one person corroded the electrical terminal, to me it was starting to corrode the fuel line. Water gets there primarily because the engine partition breaks and drips down between the airbox and the rear plastic cowl.

The center piece of the partition now sold by BMW is made of plastic and it's much more sturdy than the cardboard like material...

You can read a lot more about it here: Error code 4B99 and 483D - Bimmerfest - BMW Forums
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