VW Jetta How To/DIY: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod|Forum Volkswagen Bora
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Thread: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

  1. #1
    6 Gears & 4 Doors Teh Chr!s is on a distinguished road Teh Chr!s's Avatar
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    Default DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    Tools Needed:
    1x Flat Head Screw Driver
    1x Ratchet And Socket Set
    1x 5mm Allen Wrench Or Allen Socket
    1x 10mm Socket
    1x Pair Of Pliers Or Channel Locks
    1x Side Cutters

    Hose Clamps
    Caps For Vac Lines
    Lines For The Catch Can

    The 1.8T Engine Just Incase Ur Unsure :P


    Step 1
    Use A Flat Head Screwdriver And Turn The 3 Securing Screws Holding The Lower(Smaller Half Of The Engine Cover) And Lift And Pull It Out And Set Aside ...... U Should See This (Pictured Bleow)


    Step 2
    Take Ur 10mm Socket And Ratchet And Remove Both Of The 10mm Nuts Pictured Below


    Step 3
    Get Ur 5mm Allen Wrench Or Allen Socket And Remove The 2x Allen Head Screws That Attack The Bracket To The Intake Manifold



    Step 4
    Pill The Corrugated SAI Hose Out Of The Way And Flip The Bracket Out Of The Way


    Pull Ur Oil Dipstick Out And Grab Ur Dipstick Tube And Pull Straight Up Gently To Remove The Tube So U Dont Break It ( Its A Good Idea To Order A New One Just To Be On The Safe Side )

    Step 5
    Once The Dipstick/Tube , The SAI Hose , And N249 Bracket Are Outa The Way Then U Can Look Under The Manifold And U Shood See This


    Theres A U Shaped Clip That Has To Come Out Right At The Base Of Where That 90 Degree Shaped Pipe Goes In ( Theres Also An O-Ring In There Make Sure U Dont Lose It Or U Will Have A Leak) .... Clean Up The O-Ring And The Opening In The Top Where Ur 90 Piece Will Go Back .... While Ur Under There Carefully Remove The OEM 90 Piece And ALL Hoses Attached To It And If U Can Pull It Out And Set Aside If Not Wait Until U Remove The Valve Cover Line And "The Hockey Puck" From The Intake Pipe And Pull The Lines Up From The Top .

    U Clip


    O-Ring


    My New Intergrated Engineering Aluminum Breather Adapter for 1.8T And A -10AN 90 Degree Fitting (http://www.intengineering.com/Billet...14999-1-2.html)



    O-Ring Goes In First , Then The Adapter And 90 Fitting Or The OEM 90 Fitting , Then The U Clip , Then The Hose That Will Route To The Catch Can.




    Take A Break , The Hard Part is Done For The Catch Can Install ( But Leave The Bracket And Lower Engine Cover Off If Ur Doing The Brake Booster Mod As Well .... If Not U Can Reinstall Both The Bracket And The Cover)

    Loosen The Clamp Holding The "Y" Pipe To The Valve Cover And Pull Off The Line


    And Then Loosen The Hose Clamp Holding The Hockey Puck In The Intake Pipe & Remove , Then Cap The Port Where The Hockey Puck Was In The Intake Pipe



    Now If Ur Keeping Ur OEM Valve Cover U Will Need To Cap This Tiny Port On The Valve Cover


    Now Mount Ur Can Wherever U Want And Run A Line From The Valve Cover To Your Catch Can & Connect The Line U Ran Earlier From The 90 Degree Elbow To The Other Port On The Catch Can



    Finished Product
    GIAC Chipped Mk3 2.8 12V VR6 GTI ~Project~
    Unitronic Stage2 Mk4 GLI 2.0T 20V w/ Built AEB Head ~Project~

    Stage2 Mk5 2.0T GTI ~Totaled~

  2. #2
    6 Gears & 4 Doors Teh Chr!s is on a distinguished road Teh Chr!s's Avatar
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    Default Re: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    Brake Booster Mod

    Loosen & Remove the 10mm Bolt Located At The Red Arrow That Holds The Hard Pipe In And Loosen The 2 OEM Clamps Located At The Green Arrows


    Pop This line Out Here and the other part of the Y Section At The Part Closest To The Intake Manifold


    Loosen The Clamp Attached To The Intake Pipe Located @ The Red Arrow And Removed The Hardline @ Green Arrow


    And Put A Cap On The Lil 90 Degree Piece Coming Out Of The Intake Pipe



    Take A Razor Knife And Cut The Jacket Of The Hose At The Rear Check Valve By The Fire Wall ........ And Below Theres What U Will Has With All The Hard Lines Removed


    Brake Booster Line And Check Valve Tucked Away .... Take Ur Line And Connect It To The Check Valve (@ The Red Arrow Near The Firewall) And Run That Straight To The Nipple On The End Of The Intake Manifold (Red Arrow At The Manifold) Run The Line In The Open Or Hide It Close To The Engine Block Like I Did.



    Cap Off Any UnUsed Vac Ports Under The Manifold And If U Got A New Dipstick U Might As Well Replace It Now And Then Once Ur Done U Can Reinstall The Bracket And Smaller Engine Cover


    What U Will Have Removed By Now And Ur Finished Product

    GIAC Chipped Mk3 2.8 12V VR6 GTI ~Project~
    Unitronic Stage2 Mk4 GLI 2.0T 20V w/ Built AEB Head ~Project~

    Stage2 Mk5 2.0T GTI ~Totaled~

  3. #3
    Junior Member 1pt8t is on a distinguished road 1pt8t's Avatar
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    Default Re: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    Great DIY writeup and picture!. I have a question: When you removed the bracket in front of the intake mani, what did you do with it? My bracket seems to have about 10 wires and hoses attached underneath it. Were you able to unclip them, or did you move them somehow? Thanks - Scott

  4. #4
    6 Gears & 4 Doors Teh Chr!s is on a distinguished road Teh Chr!s's Avatar
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    Default Re: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    Quote Originally Posted by 1pt8t View Post
    Great DIY writeup and picture!. I have a question: When you removed the bracket in front of the intake mani, what did you do with it? My bracket seems to have about 10 wires and hoses attached underneath it. Were you able to unclip them, or did you move them somehow? Thanks - Scott

    i had to unclip the far left plug to be able to flip that bracket out of the way to do werk ... eventially i will delete it all together when i do my full emissions system delete ( DIY will follow that mod as well ) BTW sry for the late reply ... for some reason i dont get email updates from here on replys or new PM's Like I Do On Vortex Or myfast
    GIAC Chipped Mk3 2.8 12V VR6 GTI ~Project~
    Unitronic Stage2 Mk4 GLI 2.0T 20V w/ Built AEB Head ~Project~

    Stage2 Mk5 2.0T GTI ~Totaled~

  5. #5

    Default Re: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    Where did you get the -10 an fitting I cant find the exact pieces that you have anywhere... Im gonna have to do this mod after ordering the eurojet pcv "fix" which doesnt seem to be the same for 2004 vw jetta gls... Lost lost lost

  6. #6
    6 Gears & 4 Doors Teh Chr!s is on a distinguished road Teh Chr!s's Avatar
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    Default

    Quote Originally Posted by vigilante_zen View Post
    Where did you get the -10 an fitting I cant find the exact pieces that you have anywhere... Im gonna have to do this mod after ordering the eurojet pcv "fix" which doesnt seem to be the same for 2004 vw jetta gls... Lost lost lost
    Yo sry man been super busy at work

    http://www.jegs.com/c/Fittings-Hose/181705/10002/-1

    U should be able to find what u need n there =D




    Sent From Mah iPhone4 Using Teh Tapatalk B!tches
    GIAC Chipped Mk3 2.8 12V VR6 GTI ~Project~
    Unitronic Stage2 Mk4 GLI 2.0T 20V w/ Built AEB Head ~Project~

    Stage2 Mk5 2.0T GTI ~Totaled~

  7. #7

    Default Re: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    i know this thread is kinda old, but i'm curious what you used to cap off the TIP?

    the caps i have are too small.

  8. #8

    Default Re: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    It you do the delete will you still be able to pass smog with out it and will the mal light come on or will it go off if you do the delete

  9. #9
    6 Gears & 4 Doors Teh Chr!s is on a distinguished road Teh Chr!s's Avatar
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    Default Re: DIY: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

    Quote Originally Posted by blackmidnite44 View Post
    It you do the delete will you still be able to pass smog with out it and will the mal light come on or will it go off if you do the delete
    I have no idea man we dont have emissions testing in central VA , and yes if u do the delete and dont put the resistors in the circuit u will have a CEL , ive even heard of people gettin a CEL even if they do the resistors , only gaurenteed way is with unitronics stage 2 custom tune ... Not sure if apr , revo , giac will do a custom emissions file. But i know for a fact that unitronic does cuz its in my car
    GIAC Chipped Mk3 2.8 12V VR6 GTI ~Project~
    Unitronic Stage2 Mk4 GLI 2.0T 20V w/ Built AEB Head ~Project~

    Stage2 Mk5 2.0T GTI ~Totaled~

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