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    Thread: DIY - 1.8t Lower PCV Hose install, pics!

    1. Member
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      03-21-2008 06:57 PM #1
      DIY - 1.8t Lower PCV Hose install

      You are all familiar with it. It's the second crappiest hose setup on the 1.8's, coming in just behind the upper Y hose. Eurojet just came out with an *excellent* replacement that is well worth the time and effort to replace. I hate doing things twice (except my 2nd timing chain is coming on strong) so do this once and don't worry about it again. Here's how you do it. Click on the pics for a supersize version.

      Parts Required
      - new Lower PCV hose (EuroJet recommended!)
      - new PCV valve (optional)

      Tools Required
      - Flashlight
      - Blade screwdriver or 8mm socket (for clamps)


      Note: As always, I can't be held responsible if you break more hoses while doing this. Please be careful!

      A treatiese on one time use clamps. They suck and they truly are one time use only. To get them off, insert a blade screwdriver in the opening and twist back and forth until you spread the clamp out a bit. Pull the lip down and out, and you can get the clamp off.

      1. Examine the new lower PCV hose. Attach the aluminum coupler and tighten the hose clamp down. Put the other hose clamps on semi-tight, so they don't fall off.

      2. Disconnect the lower PCV hose from the crankcase ventilation hose (affectionately called the "Upper Y Hose")

      3. Disconnect the PCV valve from the lower PCV hose. The valve is under the intake manifold and hard to see. It should be connected to the top of the lower PCV hose.

      4. Disconnect the lower engine block connector from the block. To do this, you will need to pull out the locking clip, and pull up on the connector. Remember there is an O-ring inside the chamber, so don't loose it or break it

      4.b. You may find it helpful to unplug the white connector to give you some work room. No, I don't know what it does.

      4.c. Stick your hands under the mass of wires and hoses like this to help you get access.

      4.d. Finally removed!

      5. Now realize that you broke the plastic lower engine block connector trying to remove it from the old lower PCV hose. Curse in disgust and liberally apply plastic epoxy to fix. Look at pretty burlesque girls while you wait for the epoxy to dry.

      6. Insert the plastic lower engine connector into the new eurojet hose and tighten the hose clamp. You will need to angle the connector as shown to make the PCV valve line and the upper Y hose line up properly.

      7. Work the lower hose into place and re-install the lower engine connector into the block. Don't forget about the O-ring and the locking clip.

      8. Install the PCV valve into the upper T on the new lower PCV hose and tighten the hose clamp.

      9. Snake the long end of the lower PCV hose however you like through the jungle of wires, but make sure you can connect it up to the upper Y hose as shown.

      10. Tighten down on the hose clamps for the upper Y hose.

      That's it! I'm not a 1.8t guy but I hope this helps out.

      Mike

      Chapter 11 Dubs: Member #001
      http://www.chapter11dubs.com
      -----------------------

    2. 03-21-2008 07:06 PM #2
      Awesome man! Very detailed.


    3. 03-21-2008 07:13 PM #3
      Nice write up... I did the exact same steps last week. I got lucky as I didnt break that plastic connector so I didnt get to curse and watch burlesque while waiting for the epoxy to dry.

    4. 03-22-2008 08:38 AM #4
      Good write up Mike. Now i dont smell oil fumes every time i drive.
      Thanks for helping me with the install

    5. Member JeremiahSOW's Avatar
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      03-22-2008 09:33 AM #5
      this is perfect. mine is covered in oil residue lol. where did you order the eurojet piece from? 20squared?
      slumz of worcester

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    6. Moderator dashrendar's Avatar
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      03-22-2008 10:14 AM #6
      on this pic here:

      does anyone know the part # for the hose that goes from the open part of the Eurojet T to the intake manifold? mine is ripped and making my car run like crap, but cant figure out the part #

      |ScArE BeAr MafIa|Low.Life.Society|WetDub|726|XBOX GT:DrNotSoHorrible

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      Dash invented the double

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      03-22-2008 11:04 AM #7
      Dash, you want the hose attached to the PCV valve here? The PCV is #6 while the hose you want is #10.

      Mike

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    8. Moderator dashrendar's Avatar
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      03-22-2008 11:20 AM #8
      thanks mike, I kind of thought that was the one I wanted, but wanted to make sure. and the updated part # for that is 06A-115-561-BK
      |ScArE BeAr MafIa|Low.Life.Society|WetDub|726|XBOX GT:DrNotSoHorrible

      Quote Originally Posted by UberDub18t
      Dash invented the double

    9. Member
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      03-30-2008 09:53 AM #9
      Where did u get the aluminum hose connector that connects to upper y-hose in pic #1?

      thank you


    10. 04-02-2008 03:01 PM #10
      That comes with the eurojet pcv valve if you buy the set

    11. Senior Member 87vr6's Avatar
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      04-02-2008 03:05 PM #11
      You make awesome DIYs!

    12. Member infamous20V's Avatar
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      04-02-2008 03:05 PM #12
      nice writeup
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    13. 04-23-2008 03:58 PM #13
      You forgot to mention that the c clip on the block is a $ITCH to get off!! Took 30+min just to get that off, ended up using channel locks (don't ask)

    14. 04-23-2008 04:21 PM #14
      Nice write up.

      I just did a greddy catch can install a week ago. After some hose fitment issues, I finally got it the way I wanted.

      If you don't get the Eurojet piece, I recommend doing a catch can.


    15. 04-23-2008 04:22 PM #15
      how do you like those gloves? Everytime i try to work with those gloves it feels like i'm gonna loose grip of everything...

    16. 04-23-2008 04:27 PM #16
      Quote, originally posted by skatingzooyork »
      You forgot to mention that the c clip on the block is a $ITCH to get off!! Took 30+min just to get that off, ended up using channel locks (don't ask)
      Oh my god, that was a *****.

    17. 04-23-2008 04:34 PM #17
      this is a very well done and detailed install.

      massive props for you man. im almost certain this will come in handy


    18. Member skydive_007's Avatar
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      04-23-2008 04:39 PM #18
      note: you will almost certainly break something else doing this job

      PSN: kookly

    19. 04-23-2008 05:11 PM #19
      Quote, originally posted by skatingzooyork »
      You forgot to mention that the c clip on the block is a $ITCH to get off!! Took 30+min just to get that off, ended up using channel locks (don't ask)

      haha yeah, with 2 of us. for those yet to do this job, it officially sucks, hard! Save it for a day when your pulling your intake manni, it will make things much easier.

      Quote, originally posted by skydive_007 »
      note: you will almost certainly break something else doing this job

      yeah, we broke the dipsick thing and where the c-clip goes trying to get the clip off.


    20. Member Manu44's Avatar
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      04-25-2008 12:22 PM #20
      I lost the dam C retaining clip!
      Quote Originally Posted by Turbio!
      I'm just imagining what it was like to have an F-22, which is a positively gigantic fighter plane, just sort of sidle up next to you in midair. Just kind of like, 'sup, dudes, aloo snackbar.

    21. 04-25-2008 12:41 PM #21
      Quote, originally posted by Manu44 »
      I lost the dam C retaining clip!

      If you press the plastic piece in good enough, you can drive around w/out the clip until you order a new one.

      Ask me how I know Mine has been off for like 2wks now, not the end of the world.


    22. Member Manu44's Avatar
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      04-26-2008 11:28 AM #22
      Quote, originally posted by skatingzooyork »

      If you press the plastic piece in good enough, you can drive around w/out the clip until you order a new one.

      Ask me how I know Mine has been off for like 2wks now, not the end of the world.

      I cant press that plastic tube on hard enough to even slide the C clip in. It's hard as hell!

      Quote Originally Posted by Turbio!
      I'm just imagining what it was like to have an F-22, which is a positively gigantic fighter plane, just sort of sidle up next to you in midair. Just kind of like, 'sup, dudes, aloo snackbar.

    23. Member gt[I]'s Avatar
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      04-26-2008 12:27 PM #23

    24. Member JeremiahSOW's Avatar
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      04-26-2008 12:32 PM #24
      mine comes in this week. hopefully it helps my small oil leak
      slumz of worcester

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    25. 04-26-2008 12:39 PM #25
      Quote, originally posted by Manu44 »

      I cant press that plastic tube on hard enough to even slide the C clip in. It's hard as hell!

      Yeah, what we did is put the o-ring back on the tube then push it in as much as possible. Then put a little motor oil on the c-clip and it slipped right on. It doesn't seem like the tube will come out so I think it's good.

      BTW: this really is a PITA ... took us four hours. Probably the hardest/most time consuming part was getting the clamp off the PCV valve. Wire cutters would have helped.


    26. Member Manu44's Avatar
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      04-26-2008 03:07 PM #26
      Quote, originally posted by friedguy »

      Yeah, what we did is put the o-ring back on the tube then push it in as much as possible. Then put a little motor oil on the c-clip and it slipped right on. It doesn't seem like the tube will come out so I think it's good.

      BTW: this really is a PITA ... took us four hours. Probably the hardest/most time consuming part was getting the clamp off the PCV valve. Wire cutters would have helped.

      I finally got it in and for the clamps, i used a dremel...very very very carefully around all those dam wires.

      Quote Originally Posted by Turbio!
      I'm just imagining what it was like to have an F-22, which is a positively gigantic fighter plane, just sort of sidle up next to you in midair. Just kind of like, 'sup, dudes, aloo snackbar.

    27. Member
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      05-01-2008 03:16 PM #27
      I busted the breather tube to the crankcase, so now I have to replace that too. I don't suppose there's a good DIY solution than buying a new tube? Thanks for the write up.

    28. 07-08-2008 08:37 PM #28
      I second the PITA and the amount of time it took
      BTW: this really is a PITA ... took us four hours.

    29. Member sappersMKIV's Avatar
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      07-08-2008 09:16 PM #29
      great DIY

    30. 07-23-2008 07:31 PM #30
      Would it be easier to replace it without removing the plastic elbow from the block connector? That seems to be the part everyone is complaining about.

    31. 07-25-2008 09:05 PM #31
      I don't think so. It otherwise seemed impossible to remove the clamp from that side. It might not be a bad idea to buy another one of those tubes though. Mine broke in half and crumbled on one end when I was trying to insert it into the eurojet piece.
      Good Luck!

    32. 07-25-2008 09:22 PM #32
      This DIY was done with my car. And the easiest way do to it would be to remove the Intake Manifold. Good thing i'm skinny and i could get my hands through it. But i think it wouldnt work out the way you wanted it to if you didnt take the black piece off.

    33. 07-25-2008 09:53 PM #33
      Yet another Great DIY from mike. I swear this guy needs a harder job.
      TDI for the win !!!!!!!!!!!!!!

    34. Member RacerX7624's Avatar
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      07-26-2008 03:48 PM #34
      awesome Write up, now i just need 2 find time to do it

    35. 07-26-2008 04:06 PM #35
      you could remove the black bracket in front of manifold to have more room to work under the manifold as you need to do to change the breather hose mentioned higher (06A-115-561-BK).
      How much is that eaurojet hose compare to oem?

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