Ok did some more digging, but am still puzzled...
With all the tubes and flanges cleaned up and clamps properly tightened, intercooler tubing does stay put
.
I did run a wire tie thru the J tube port and took apart and cleaned the CCV. Both seemed pretty clean from the start so I don't think that was the problem, but they are definitely clean now.
I have to change my comments on turbo shaft play. I did a test while it was still hot/warm and could detect some play that I did not feel before. Have not measured with any tools, but "guessing" from moving things with my fingers, feels like 1/16" in-out play on the shaft, maybe a touch more. Very little, maybe .005" up-down and left right. And when I went back after it had cooled, I could feel that play then too, but had to push it a bit to get it "loose". I don't know if that is enough to start worrying about the turbo, anyone here have any guidelines. When I checked the forums here, there is a wide range of answers on this; anyone know what the good/bad cutoff points are for turbo play??? From my experience with TDIs that much turbo play isn't too bad, but I wonder if it could be causing all this oil in the intake?
There definitely is an oil leak, comes down the left side of the engine in back, runs along the case behind the starter. The wires above this are getting oil soaked too. But the rubber coolant hose a bit higher to the EGR seem clean. Intake bolts on that side are tight (at least all the ones I could reach with the common rail installed), and I don't see any oil traces from that high (although it's a bit hard to see in back). There have been drops of oil collecting on the bottom of the FCV. And after cleaning everything up, and going 5 miles for a test drive, when I pull the intercooler to FCV hose at the FCV, there is a bit of engine oil in there on the FCV flange and a bit more in the hose (like 1 teaspoon). So it seems likely that oil coming thru the intake is the source although could be two problems I guess).
So I am not real clear where to keep looking at for this leak. I suppose I could clean things up again, do a temporary EHM so that no CCV oil is getting into the intake, and see if I find oil again in the FCV after a few test miles. Then it would have to be turbo or in the intercooler. And I suppose I could also pull the intercooler and see how much oil has collected in there (it's 10k miles old).
One other maybe complicating factor. I put in a WW style block off plate while doing the other work (thanks WW). The car supposedly has a EGR delete tune, but I am pretty sure it isn't working, cause the oil gets black very fast and when I pull the MAF plug it throws a P0102 code, which was supposed to be blocked. Anyhow I put that plate in there to help reduce carbon. But I got to wondering, with no air/exhaust flowing thru that pipe when the FCV closes, could that be allowing intake oil to run down and collect in that tube (it is a low spot), and maybe leak out if a lot is just sitting there? (and perhaps even spike the boost pressure if the FCV is blocking the intake) I know the FCV is working cause I hear it release just after I turn the engine off, so I assume it is closing at other times too (thus the pulling of the MAF plug and P0102). Just curious what happens when one puts in a block off plate but the tune you have is still trying to work the FCV. Anyone know how this works or doesn't? I do plan on getting a GDE eco tune, but was waiting until all the other issues were "fixed" (haha).
Any other engine oil leak sources on the left rear side of the engine that would leak down behind the starter and wet the wires in that area?
Thoughts, suggested test?
TIA