I had this problem with the sump breather valve since last year-I/C full of oil, and under boost the oil was getting sucked from sump in to intake system. In Dec 04 found out that the valve does not does its job-the membrane was eaten away by oil.
Fitted brand new valve-couple of months in, and the same story.
Found the thread here about catch tank been used on 2.5 TDI from A6. Ordered. It was smaller than I expected, but never mind.
Fitted this catch tank in to the breathing system. Just needed to block the drainage hall in the catch tank. Have no return oil line to the sump. Blocked the pipe that goes into inlet(the one that just before turbo inlet) and attached small breather filter, to vent the fumes.
The problem is that the fumes are realy getting inside the car.
Solution: this original audi breather has a internal plastic valve, as opose to the breather valve. So I connected exit pipe from the breather back to the air inlet pipe.
This been done last w/end, ans since then everything seems alright. I think the plastic valve inside the breather will do the job much more better than membrane.
Some pictures attache-plumbing looks abit strange, but with lomited resources it works.
BTW-since this conversation and decent Jubilee superclaps between the IC and intake pipe the boost holds. And my previous boost cut outs at 4000rpm probably have been related to this and very dirty intake T sensor on the IM. Cleaned the sensor with the IPA and problem gone.
For NOW 
Fitted brand new valve-couple of months in, and the same story.
Found the thread here about catch tank been used on 2.5 TDI from A6. Ordered. It was smaller than I expected, but never mind.
Fitted this catch tank in to the breathing system. Just needed to block the drainage hall in the catch tank. Have no return oil line to the sump. Blocked the pipe that goes into inlet(the one that just before turbo inlet) and attached small breather filter, to vent the fumes.
The problem is that the fumes are realy getting inside the car.
Solution: this original audi breather has a internal plastic valve, as opose to the breather valve. So I connected exit pipe from the breather back to the air inlet pipe.
This been done last w/end, ans since then everything seems alright. I think the plastic valve inside the breather will do the job much more better than membrane.
Some pictures attache-plumbing looks abit strange, but with lomited resources it works.
BTW-since this conversation and decent Jubilee superclaps between the IC and intake pipe the boost holds. And my previous boost cut outs at 4000rpm probably have been related to this and very dirty intake T sensor on the IM. Cleaned the sensor with the IPA and problem gone.
For NOW
?
, i'll look at that when i get home, Just found some numbers on Vagcat
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