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15 March 2008

PCV Replacement and Eurojet Valve

Edit: November 2008 - I've removed the EuroJet valve and replaced the PCV system with a vacuum-only plate from BSH.


This thread in the 2.0T FSI Engine Forum on VWVortex gives good background information and diagrams relating to the PCV/Crankcase Breather system on the 2.0T FSI engine. The part numbers and description of the various revisions of the valve (current as of early 2008) are illustrated in this thread.

I've been running the Eurojet Racing checkvalve that protects the PCV system for a few months, but decided that I wanted to make sure all PCV components were in top condition. I decided to replace the rear PCV tube with the one that has an integrated checkvalve, and replace the front PCV component with the one that still has 2 internal checkvalves (a non-standard combination of parts). The Eurojet valve would then contribute to protecting the new components, and would give a total of 4 checkvalves in the system.

The parts I installed are:

06F 129 101 F New breather ('PCV') valve
06F 103 215 A New pipe with checkvalve
06F 103 483 E Gasket
06F 145 757 F Gasket


This is the new rear pipe with the integrated checkvalve (06F 103 215 A):



Remove the engine cover/airbox.

To remove the two bolts that hold the pipe to the turbo inlet you will need a 5mm hex bit, universal joint, short extension and compact ratchet handle. The lower bolt is easy to get to, the upper one is a pain. There is a metal gasket between the pipe flange and the turbo, and a heatshield on top of the flange that you will need to carefully move from behind the oil line. (If you drop the bolts, they will mostly likely not fall all the way through to the ground - they will land on a chassis crossmember. That crossmember has little compartments on top, and reaching them to retrieve a dropped bold requires some contortion. I speak from experience, you have been warned.)

You will also need to remove the one-time-use clamp that joins the pipe to the rubber hose segment.

This is the heatshield that will be removed:


This is how the heatshield orients on the pipe. This is important for when you install the new one.


This is the metal gasket, note the locating tab on the upper part of the flange:


The 'gasket' has little tabs that catch on the bolt threads, so putting the bolts in a few turns helps hold the whole assembly together for reinstallation:


This shows where the pipe flange bolts to the turbo inlet. See the flexible silver heatshielding on the oil line running from the head down to the turbo? You will need to tuck the metal heatshield (pictured above) behind this line without pinching the silver fabric.


Rear pipe finally installed. I used a stainless-steel screw clamp instead of one of the original-style clamps. Don't tighten it too much, you don't want to damage the pipe and the checkvalve at that end.



The front PCV component is easily removed with 4 screws (T-25 torx head) and 2 snap-on pipes. The new one (06F 129 101 F) is a direct replacement, very straightforward. Before installation, however, I attached the Eurojet checkvalve to it since it requires quite a bit of twisting and effort to get it into the very tight silicon tubing. Lubricating the ends of the tubing helps it go on.

Old (revision C) on the left, new (06F 129 101 F) on the right:


Old:


New (06F 129 101 F):


Old:


New (06F 129 101 F):


The Eurojet PCV checkvalve assembly:


The hoses on the Eurojet valve are lined to protect against damage from oil residue. Be careful not to damage the ends of this lining when you install the hoses, since fragments of the lining can and will jam the valve.


This is an exploded view of the valve, and illustrates the orientation of the valve when installed. The upper part in this photo attaches to the PCV valve, and the lower part in the photo attaches to the intake manifold:


Another view showing the rubber valve seat:


The piston in the valve had some rough barbs when I first got it. Before installation I smoothed them out with some 1000-grit sandpaper. The piston seems to be fairly soft brass so it smoothed out easily.



This is how the whole thing looks when installed.


In order to make the valve fit under the stock engine cover, I unscrewed the mounting peg that the engine cover snaps onto nearest the valve. Unscrewing it about halfway seems to be just enough. I'll probably add a nut to lock the peg in place and prevent it from further loosening, but this little bit of elevation does the trick perfectly.


Edit: November 2008 - I've removed the EuroJet valve and replaced the PCV system with a vacuum-only plate from BSH.

The hose on my EuroJet valve cracked. EuroJet sent me a replacement assembly.

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