Update: Jim at dieselgeek called me and told me about the improved o-rings, which he is sending to me. Hopefully, that will work.
Earlier this year I purchased several of the dieselgeek products for my 2003 Jetta TDI ALH, which I'm very happy with, including the oil bypass filter kit with the valve cover return. I'm having an oil leaking problem due to the Kynar tubing, and I hope someone can suggest a remedy.
Here's the link to the dieselgeek product: http://www.dieselgeek.com/servlet/Detail?no=462
The oil leak occurs at the Kynar tubing connection on top of the aluminum bypass filter base. Thinking that I may have accidentally cut the original Kynar tubing too short that was provided with the kit, thus causing the leak, I purchased more Kynar tubing from U.S. Plastics Corp. Last night, I cut a new piece of tubing that was slightly longer than the original, making sure that the ends were as square as possible, and installed. I pushed the tubing into the fittings as far as humanly possible as directed in the bypass instructions, started up the car, and everything seemed fine. I then put the engine cover back on.
This morning on the way to work I stopped halfway, popped the hood, took off the engine cover, and discovered oil on top of the aluminum filter base again. Ugh!! So at this point I'm not sure what to do to stop the leaking, and hope someone can suggest a fix. One thing I thought of is to leave the engine cover off or modify it in some way because I'm thinking that it may be pressing on the Kynar tubing and thus compromising the seal in the fitting. I'll try this on my way home from work, and hope for no oil leaking.
I'm sort of surprised by this Kynar tubing approach for the oil return. It seems to me that the hard Kynar will never seal correctly to the metal fitting on top of the aluminum bypass filter base. I'm curious as to why a fitting similar to the teflon-lined braided stainless oil feed line wasn't used for the return line to prevent such problems.
So, can anyone make any suggestions? If I can't get the oil to stop leaking then I'll have no choice but to remove the bypass. Since I chose the valve cover return option, having to uninstall the bypass filter means I would need to purchase a new valve cover. Not ideal.
I did send the owner of dieselgeek an e-mail describing my problem, but thought that maybe someone in the MyTurboDiesel community might have experienced the same problem and come up with a fix. I know the easy answer is to leave the engine cover off, but if possible I don't want to do that.