An oil leak from the EGR valve vent holes (under the actuating diaphragm housing) is normal, but I would not consider any other major oil leaks to be normal and I would advise further investigation.

One problem which is emerging as these (splendid) old 1.9 PDs age, is a blockage in the "puck" on top of the rocker cover which acts as an oil separator for the crankcase breather system. The consequence of a blockage here is that the blowby gases over-pressurise the crankcase and prevent the turbocharger's bearing unit from draining properly unimpeded into the sump.

This gives rise to excessive lubricating oil in the intake from the compressor shaft seals which will fill the charge pipes and intercooler. IF NEGLECTED, ENGINE RUNAWAY CAN OCCUR. Any diesel engine will quite happily ingest its own lubricating oil (or any other available hydrocarbon such as propane gas) and will run independently of governor control. This is an unsafe condition.

Some dealers will fit a replacement turbocharger in these cases, whereas a clean-out of the breather system is often all that is required. The long oil change intervals allowed under the VAG "sop to the corporate owner" scheme have probably contributed to this problem, and many of these engines now have covered very substantial mileages.

659.

You can't clean the breather effectively, it is moulded into the cam cover so you have to fit a new cam cover but I work on the VAG PD day in day out and hardly ever see one blocked. Oil leaking from the EGR valve is the same oil that bleeds out of the hoses and which I see even on two year old cars with less than 20K on them, it is quite normal. When oil leaks from the vent holes on the EGR valve it means the valve is worn and could be replaced to stop the oil showing but it is only necessary if the owner is perplexed by the oil. VW introduced thicker seals for the boost pipes to stop the oil showing but it does not stop it from being there inside, it’s a case of what the eye can't see the mind does not worry about.

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Edited by Crasher on 04/11/2012 at 14:00