Please contact me if you have pictures for this or complete it and take pictures on the way. I will add them to this post. 03_uni-b
I take no responsibility of any damage done to your vehicle. Use these instructions at your own risk. You know your capabilities.
That being said, lets get started...
Most of what is shown here is applicable to all 1.8T engines.
For this DIY, I am replacing the stock diverter valve with the VW.OEM TT Bypass Valve (part # 06A.145.710.N), and two medium size hose clamps, and one small hose clamp
1. A medium size flat-blade screw driver
2. Needle nose pliers, tin snips, or a dremel with a cutting disc to cut the one-time only clamps
3. Some motor oil or vegetable oil
Step 1 - Remove engine cover
Step 2 - Locate the stock diverter valve
Step 3 - Remove the hoses from the stock diverter valve. To do this, you will need to cut off the one-time use only clamps. You may use needle nose pliers, or you can break the "loop" part of the clamp with strong tin snips or use a dremel with a cutting disc. Warning: If you choose to use a dremel, it will cut through the clamp like butter, be careful and keep your hand steady so that you do not accidentally cut into the hose.
Step 4 - After cutting off the one time use hose clamps, remove the hose from the top nipple. Then remove the hose from the bottom nipple. After that remove the hose from the side nipple. The Side nipple may be a little bit difficult to slide out but give it a strong tug. DO NOT DROP ANYTHING INTO THESE OPEN HOSES. After removing your stock valve, put the hose clamps on the bottom and side hoses. (In the picture I have the small hose clamp also on the top hose. Do not do this because you will be risking dropping the small hose clamp into the open hose on the bottom)
Step 5 - Put some vegetable or motor oil on the bottom and side nipple of the new diverter valve that you are installing. This will help it slide into the hoses. In the picture the stock diverter valve is on the right and the new diverter valve is on left.
Step 6 - Install the new diverter valve. Put the small hose clamp on the upper hose and put it on the top nipple. Tighten all hose clamps
Step 7 - Put your engine cover back on and you are done
Modified by rockon217 at 12:29 AM 11-2-2006
Modified by rockon217 at 10:20 AM 11-2-2006