ReRouting CCV lines on E300 [NON-Turbo] - PeachParts Mercedes-Benz Forum

michakaveli · #1 02-21-2004, 02:58 PM

Question for you MB diesel techs. Currently I have removed the crossover tube, EGR assembly and the black plastic valve cover cover. In glancing at the CCV system, I can see that I can easily reroute the CCV vent tube from getting back into the intake tract. There is a CCV valve right on top of the opening coming out of the head.
I want to run some heater hose right after the CCV valve, running forward toward the front of the head and out of the side opening [turbo's have this opening utilized to blow out CCV gases right before the turbo], and run it to the ground outside. Turbos I assume can utilize this in order to keep the turbine lubed. Stock routing of the CCV on my non-turbo lets it run right to the opening at the end of each intake runner per cylinder.

When reading previous threads I made the assumption that leaving the CCV system as is helped lube the resonance flaps in the intake system. Under futher examination the resonance flaps are way before the CCV gases even reach them, offering no assitance in lubrication.

MY focus for considering this effort is in affect to aid keeping my air intake tract clean and utilizing my latest mod of allowing the EGR valve to draw fresh air. In addition I like to keep the top of my engine clean from all the oil that accumulates due to the CCV valve

#2 02-21-2004, 04:21 PM

The CCV system serves no lubrication purpose, turbo or not. On my New Beetle TDI, I just ran a piece of flexible plastic tube from the top of the valve cover to the bottom of the engine compartment, and pointed it towards the back of the car so that it would vent to the atmosphere without restriction/interference.

michakaveli · #3 02-21-2004, 05:59 PM

Here are some pix with the corssover intake off.....

And The CCV leaking... Nothing big but I don't like it dirty

I will take pictures after I add the new CCV line.

#4 02-21-2004, 07:12 PM

Very interesting looking without the crossover pipe on. Is the plate on the first exhaust manifold where the EGR used to be?

michakaveli · #5 02-22-2004, 05:02 PM

So far she runs like a beaut. It's kinda cool seeing the CCV gases vent from underneath the car. Kinda reminds me of the city buses that you see idling when stopped.

SW · #6 02-22-2004, 05:53 PM

Just curious, with the setup you have, how much oil is lost? Is it a measurable amount or totally negligible?

michakaveli · #7 02-22-2004, 06:16 PM

Quote:

Originally posted by SW
Just curious, with the setup you have, how much oil is lost? Is it a measurable amount or totally negligible?

Technically there shouldn't be any loss. The CCV valve is still in place. Instead of the gases going back in through the intake and being burned they are being vented outside.

slowmoe · #8 02-23-2004, 03:57 PM

michakaveli, (or others)

This seems like a very elegant solution. After doing my glowplugs a few weeks ago, I was astonished by the amount of build up in the intake. I too would love to reduce this as much as possible. However, I want to make sure that in so doing I am not compromising any other related components. A few questions:

What does CCV stand for?

What was its origional design intention?

Why is it not necessary?

Have you seen any impact on performance?

michakaveli · #9 02-23-2004, 04:28 PM

What does CCV stand for?
CrankCase Ventilation.

What was its origional design intention?
Used to be burned off and keep the oil vapors from getting into the atmosphere. Partially emissions regulated. A way to keep everything contained in the engine.

Why is it not necessary?
It still exists, it is by all means necessary. Just rerouting the gases from traveling through the intake and prechambers, etc. Getting rid of it instantly to the atmosphere. The CCV gases enter at the end of the intake, right before air enters the engine. I assume that this vapor goes into the prechamber, over time making a nice glue and solidified carbon build up, not allowing glow plugs once unscrewed to be removed. (I could be wrong, but a good guess non-the less).

Have you seen any impact on performance?
Since I've cleaned the crossover tube, sprayed the resonance flaps with brake cleaner and re-lubed them with a few drops of oil, reassembled, throttle response is just butter. Really smooth acceleration. On the highway now when I punch it, it revs up to like 4000k like before but has a firmer kick when it keeps going. Wasn't as noticeable as before.

But I'm glad now that with the EGR blocked and the Crankcase vapors rerouted, only fresh air enters the entire intake tract and into the engine. If I am wrong about any of my assumptions guys please respond.

#10 02-23-2004, 05:00 PM

The smoother acceleration is because you have bypassed the EGR. This will also contribute to more power in the upper RPM range. When I bypassed the EGR in my New Beetle, throttle response, power, and smoothness was increased a LOT. I don't think the CCV bypass will provide more power instantly, but it will definitely keep the intake and prechambers free of oily goo, which will prevent power loss in the future.

michakaveli · #11 02-23-2004, 05:17 PM

Quote:

Originally posted by VeeDubTDI
The smoother acceleration is because you have bypassed the EGR. This will also contribute to more power in the upper RPM range. When I bypassed the EGR in my New Beetle, throttle response, power, and smoothness was increased a LOT. I don't think the CCV bypass will provide more power instantly, but it will definitely keep the intake and prechambers free of oily goo, which will prevent power loss in the future.

It wasn't instant.... I drove around prolly 30-50 miles highway till the throttle response smoothed out. I think what really helped was cleaning off the rosonance valves and dropping a few drops of oil on the spots where the pivot.

Just got home from work and I touched the cross-over tube and it was nice and cold, the intake manifold was noticeably cooler as well....

No doubt about it that the engine response is a lot smoother overall with the EGR mod and CCV combined.

My next task is to increase my MPG's. Been using Primrose to help "condition" my fuel system.

The SAGA continues...

#12 02-23-2004, 05:21 PM

In theory, you will get a slight increase in fuel economy while cruising at a steady speed with the EGR disconnected due to the increased oxygen content of the intake air, and thus more complete/efficient burn. Maybe 1 or 2 MPGs.

190D22 · #13 02-23-2004, 11:02 PM

Hey mich, I was just on your website looking at the pics of your car. I'm sorry if I've missed something somewhere... but have you changed your tail lights?? I love the updated 210 tail lights, it makes your diesel even better!

michakaveli · #14 02-23-2004, 11:17 PM

Quote:

Originally posted by 190D22
Hey mich, I was just on your website looking at the pics of your car. I'm sorry if I've missed something somewhere... but have you changed your tail lights?? I love the updated 210 tail lights, it makes your diesel even better!

190D22...

The lights are indeed the updated MY00+. I personally like the new tail-lights on the new w211 cars, but I do wish that they continued onto the trunk lid like the w210. Can't have everything I guess

michakaveli · #15 02-24-2004, 12:06 AM

One more picture I forgot to add.....