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HowTo: PCV System Replacement |
| Last updated: 6/23/2008 |
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The stock PCV system is pretty crappy on later model 1.8T's. The AWD's had metal hard pipes
but for some reason VW got cheap and now we all have problems.
After I hit 60k miles on my car I decided to redo the system. I am using a mixture of after market
and stock parts, as well as silicon line to make the upper pipe match my inline
catch can.
The key to this was the introduction of the EuroJet lower PCV silicon hose that I'm utilizing. Also
you do not need to replace the lower hard pipe bend but a lot of people break these when they try to replace the valves. I decided to not mess around
and just replace it with the seal and clip as well as a new PCV valve.
The silicon hose is for the upper portion of the PCV system that will route through my DIY catch can and into the
"ufo" thing on the intake pipe. This replaces the horrible prone to break Y pipe. EuroJet also makes a Y pipe replacement but since I'm
using the catch can I decided to make my own setup with a T splitter and some silicon line....
The difference between this and my previous DIY catch can setup is that this no longer utilizes the stock lines. It's a total replacement for them.
Equipment:
- EuroJet Lower PCV Hose
- Stock PCV Valve (Part 035-103-245-A)
- Lower hard pipe bend (Part 06A-103-213-F)
- Clip for lower hard pipe bend (Part 037-121-142-A)
- Rubber Seal for lower hard pipe bend (Part N-904-673-01)
- 1 inch ID high temp silicon hose
- 3/4 inch ID silicon hose
- 3/4 inch silicon line extender (Mine is metal)
- Plastic T splitter (1"x3/4"x3/4")
[You can find these at ground sprinkler supply sites.]
- Hose Clamps
Tools:
Here's what it looks like when you are done:
Installation:
The first step is removing the old PCV system. The whole thing from the engine block to the
Y connector that hits the TIP.
Replace the lower hard bend pipe using the seal and the clip and attach the EuroJet pipe to it. Make sure
to put the PCV in before you are down there, just put it all together under the car. Sorry, no pics, can't fit
the camera in there! Just pay attention to how it's set up before you remove the old parts, it's not that difficult.
Now you have the lower pipe sticking up where the old Y pipe connected previously.
Using a 3/4 inch connector mate some line to it and attach to one of the 3/4 inch ports on the plastic T.
Attach the 1 inch high temp line to the valve cover port and attach the other end to the 1 inch port on the T.
Cut a small piece of the 3/4 inch silicon and attach it to the catch can and the other 3/4 inch port on the plastic T.
This should be on the TIP side now.
Run the remaining distance from the catch can to the TIP port with 3/4 inch line.
That's it, you now have a DIY catch can and PCV replacement that is not going to fall apart like the stock one!
Enjoy!
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