FCV oil leak????

MRausch82 · **Posted:** Fri Oct 04, 2013 8:28 am

Yesterday while changing the oil in my CRD, I had noticed I had an oil leak. I noticed last time I changed oil that there was a little bit of oil dripping down one of the bolts of the bell housing. I didn't think too much of it at the time, but noticed it again yesterday and decided to investigate. I traced it up to the gasket between the flow control valve and the intake elbow. It is not the Intercooler hose itself. That was replaced last year. I took it off and inspected it and it is fine. It appears that it is likely spraying some oil due to their crankcase ventilation system while under boost. It was enough that it has built up on that side of the engine and was dripping down. This is probably been happening for a while. It's not enough that I have to ever Add any oil, but it's an annoyance. My question is this: it appears that there is a gasket between the flow control valve and the elbow, not an O-ring. I say this because I can see the gasket sandwiched between the FCV and the intake elbow. Looks to be the same gasket As between the intake elbow and the intake manifold. They both have the little tit on them that sticks out. I could feel it and it felt like paper (no comments). I see that ID Parts has a gasket kit for these which consists of two of those paper gaskets and an O-ring. My curiosity is a: what do I need? B: is there supposed to be a paper gasket there as well as an O-ring or is it supposed to be an O ring only? From what I can tell all that is needed for that entire assembly is one O-ring and one paper gasket, the paper gasket going between the elbow and the intake manifold, and the O-ring going between the FCV and the intake although… Am I right? I suspect that either when they replaced my FCV a couple of years ago instead of putting an O-ring they used a paper gasket, that, or when they replaced my glow plugs last month and they removed these pieces to gain access, and instead of replacing it with an O-ring they replaced it with a paper gasket…

Hexus · **Posted:** Fri Oct 04, 2013 8:42 am

There are paper gaskets on both sides.

Mopart Part #'s are

5066946AA
5142613AA

ID Parts sells both of them.

The bolts on that elbow are a real pain in the hindquarters to access, if you think the timing belt was bad, this is worse... get your wobble socket and about 30" worth of extensions ready.

Also, you have to be VERY careful with those bolts, as they are prone to strip if you over-tighten because they're screwed into the aluminum intake on the top side. I have personally had to helicoil 2 of mine.

The biggest caveat would be to ensure you clean off 100% of the old gasket before you attempt to apply the new, you should also go ahead and clean the existing crap out of that area while you are in there.

Call me if you need more information or insight, it's a real PITA.

geordi · **Posted:** Fri Oct 04, 2013 11:55 am

The o-ring is between the end flange where the hose attaches, and the FCV proper. The FCV and the intake elbow are separated by a paper gasket, and the elbow and the intake are separated by the same paper gasket.

Now if you are feeling her tits and they feel like paper... Well, that just means you haven't spent enough money to excite your Italian mistress yet.

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TJ2 · **Posted:** Fri Oct 04, 2013 9:26 pm

IIRC, I got the piping and FCV off before removing the intake elbow. If the elbow to intake gasket isn't leaking, I wouldn't take it off. It's the one that's a bear to get the bolts back in.

One exception might be if the glow plugs haven't been updated. . . that elbow has to come off to access #3 gp.

I would also have gaskets and O ring in hand before I started the job. Or make the gaskets and use red RTV to seal the flattened O ring.

geordi · **Posted:** Fri Oct 04, 2013 9:56 pm

Believe it or not - I didn't replace (or need to) any of the paper gaskets on the rocker or glow plug jobs on my trip. They all opened up clean and went back the same way.

MRausch82 · **Posted:** Sat Oct 05, 2013 12:44 pm

After I got home from yet another 250 mile day for work, I carefully checked where the oil is coming from... It is coming from between the "flange" that bolts to the front of the FCV. That is where the paper gasket is located, not between the FCV and the elbow... I was mistaken. What could cause it to leak? It is going in next week since they had these parts off to do the glow plug update for me at the dealership last month, and the two gaskets and one O-ring are on the invoice that pertain to the FCV. I figure it is under warranty, why get my hands dirty? I am also getting an alignment while I am there. Since I am friends of the owner of the dealership, I know they will take care of me. They are good folks... one of the few dealers that do not suck...

papaindigo · **Posted:** Sat Oct 05, 2013 1:44 pm

The cause of the leak would be a bad seal/leaky gasket combined with boost pressure being enough to force a bit of the oil that comes from the CCV "hockey puck" thru the turbo and CAC hoses to the FCV thru the fitting.

MRausch82 · **Posted:** Sat Oct 05, 2013 6:03 pm

papaindigo wrote:

The cause of the leak would be a bad seal/leaky gasket combined with boost pressure being enough to force a bit of the oil that comes from the CCV "hockey puck" thru the turbo and CAC hoses to the FCV thru the fitting.

Exactly. I figured as much. :mrgreen:

It's an annoyance. At least I don't have to add a drop of oil through the oil change intervals. It does not use a drop. Never has.

danos_007 · **Posted:** Wed Oct 23, 2013 11:02 pm

Problem is the oil, not the leak. There shouldn't be oil in there. It will plug your intake.

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geordi · **Posted:** Wed Oct 23, 2013 11:17 pm

The oil is harmless if the EGR isn't adding filth that mixes with the oil to create immovable sludge.

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MRausch82 · **Posted:** Thu Oct 24, 2013 1:55 pm

geordi wrote:

The oil is harmless if the EGR isn't adding filth that mixes with the oil to create immovable sludge.

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Correct. I have worked on lots of diesels that put the CCV vapors back into the intake. The oil won't harm anything, but when the EGR is in use, the oil and the soot combine and make a mess, and will together combine and plug things up. My EGR is disabled with the ORM and has been since 47K. I am not at 96K.

dgeist · **Posted:** Thu Oct 24, 2013 3:02 pm

Realistically, I would think that's one of those spots that could leverage a "RTV shmear" gasket if your paper or O-ring happened to need replacement and it wasn't convenient to get a new one. Nice part is if you want to go back to factory, peeling off the silicone and a plastic scraper once-over is all you'd need.

It is strange that it would have a leak there. It's not a high-wear kind of item unless you soak it in a chemical that softens it or is gets jammed in there crooked, etc.

Dan

MRausch82 · **Posted:** Thu Oct 24, 2013 3:10 pm

dgeist wrote:

Realistically, I would think that's one of those spots that could leverage a "RTV shmear" gasket if your paper or O-ring happened to need replacement and it wasn't convenient to get a new one. Nice part is if you want to go back to factory, peeling off the silicone and a plastic scraper once-over is all you'd need.

It is strange that it would have a leak there. It's not a high-wear kind of item unless you soak it in a chemical that softens it or is gets jammed in there crooked, etc.

Dan

It leaked after the glow plugs were replaced. It had to be removed, and they did use new gaskets. Not sure what happened. They replaced them again, and it appears RTV was also used (black), and it is leak free. I'm happy it is not making a mess anymore. See my post on "starter area leak" as this was all part of this issue, now resolved.

geordi · **Posted:** Thu Oct 24, 2013 4:42 pm

Probably the dealer replaced the gasket, but didn't bother cleaning off all the old gasket schmutz that would have been there. Doesn't take much at all to create a nice leak with hot oil. (The air temp of the intake post-turbo is easily in the 150 degree range if not more)

My TDI came with a nice oil leak at the front end. Wasn't huge, but was enough to drool and cover the underbody in filth. Front end? What is there to leak oil? Turned out to be one of the o-rings on the oil-to-coolant heat exchanger under the oil filter. A TINY sliver of aluminum got pinched in the ring that only seated against a flat surface, and the oil pressure and thin hot oil was enough to work itself past and create the drool.

Wiped everything down with towels and reassembled exactly as it was - leak is gone and the underbody is staying much cleaner.

CATCRD · **Posted:** Thu Oct 24, 2013 10:41 pm

MRausch82 wrote:

geordi wrote:

The oil is harmless if the EGR isn't adding filth that mixes with the oil to create immovable sludge.

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Correct. I have worked on lots of diesels that put the CCV vapors back into the intake. The oil won't harm anything, but when the EGR is in use, the oil and the soot combine and make a mess, and will together combine and plug things up. My EGR is disabled with the ORM and has been since 47K. I am not at 96K.

It still rots your intake hose(es).

geordi · **Posted:** Thu Oct 24, 2013 11:30 pm

On the CRD, the factory hoses are subject to degradation from the oil. On the TDI and many other diesels, non-oil-permeable hoses were selected by the factory engineers. For the CRD, Samco silicone hoses are an excellent upgrade.

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CATCRD · **Posted:** Fri Oct 25, 2013 9:54 pm

geordi wrote:

On the CRD, the factory hoses are subject to degradation from the oil. On the TDI and many other diesels, non-oil-permeable hoses were selected by the factory engineers. For the CRD, Samco silicone hoses are an excellent upgrade.

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Yes I have them on both CRDs. I was referring mostly to the airbox to turbo hose, for which there is no Samco version. It is rotted out without some kind of Provent system.

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

MRausch82 wrote:

After I got home from yet another 250 mile day for work, I carefully checked where the oil is coming from... It is coming from between the "flange" that bolts to the front of the FCV. That is where the paper gasket is located, not between the FCV and the elbow... I was mistaken. What could cause it to leak? It is going in next week since they had these parts off to do the glow plug update for me at the dealership last month, and the two gaskets and one O-ring are on the invoice that pertain to the FCV. I figure it is under warranty, why get my hands dirty? I am also getting an alignment while I am there. Since I am friends of the owner of the dealership, I know they will take care of me. They are good folks... one of the few dealers that do not suck...

OP, I think I have the same issue as you. I have the slow oil leak seemingly coming from the FCV or intake elbow area. Going to dig in this weekend and replace glow plugs at the same time.

Did you notice a boost leak along with the oil leak? Mine was making some bizarre buzzing sounds under boost which turned into rushing air.

See my post here: viewtopic.php?f=5&t=73945

FCV oil leak????

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