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MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

DIY
1 reading
177K views 65 replies 16 participants last post by  Teh Chr!s  
#1 · (Edited)
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 O0 :p
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Step 1
Use A 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)
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Step 2
Take Ur 10mm Socket And Ratchet And Remove Both Of The 10mm Nuts Pictured Below
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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
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Step 4
Pull The Corrugated SAI Hose Out Of The Way And Flip The Bracket Out Of The Way
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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
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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
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O-Ring
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My New Intergrated Engineering Aluminum Breather Adapter for 1.8T And A -10AN 90 Degree Fitting (http://www.intengineering.com/Billet-Aluminum-Breather-p8914999-1-2.html)
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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.
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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
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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
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Now If Ur Keeping Ur OEM Valve Cover U Will Need To Cap This Tiny Port On The Valve Cover Or The Oil Vapors Will Come Out Of Here
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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
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Finished Product IF U Are Keeping The N249 And All That Jazz
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#2 · (Edited)
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
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Pop This line Out Here and the other part of the Y Section At The Part Closest To The Intake Manifold
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Loosen The Clamp Attached To The Intake Pipe Located @ The Red Arrow And Removed The Hardline @ Green Arrow
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And Put A Cap On The Lil 90 Degree Piece Coming Out Of The Intake Pipe
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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
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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.
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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
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What U Will Have Removed By Now And Ur Finished Product
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Finished Product If Ur Deleting Them And Cleaning The Clutter Up
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#3 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

..... There ... If U Still Manage To Eff It Up Leme Know Ill Do What I Can To Helps
 
#6 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

yea but i go back to work in a few hours and dont have off until Thursday

its not getting done b4 wf
 
#7 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

What about all the extra check valves that came off with the hoses? Do they matter? And will you be doing the Blue ball delete and such too? This is alot easier to follow than the others online.
Good looking out mayn!
 
#8 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

What about all the extra check valves that came off with the hoses? Do they matter? And will you be doing the Blue ball delete and such too? This is alot easier to follow than the others online.
Good looking out mayn!
ALL Of That Check Valve Bullshyt Gets Deleted And The Spare Vac Ports Are Capped Off And U Just Run A Line Straight Off Of The Manifold To The B.Booster Line ....Less Shyt To Fail And Less Possible Boost /Vac Leaks .

And Yes I Plan To Do A Full Emissions System Delete ....I Already Have The Custom UNI Stage 2 File With The Emissions CEL's Deleted
 
#12 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

That'll look awesome bro!!!!

Hey, does that mod for the brake booster line cause any CEL?
Nope No CEL's Ur Just Deleting All Them Stupid Extra Lines And Running One Solid Line.
 
#14 ·
#15 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

Trying to find a 10an O-ring boss 90* to twist tite or hose end fitting for the IE Billet Adapter but there is not much to choose from. How'd you go about making the 90* fitting?
 
#16 ·
#17 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

And here I thought it was one piece. Ha! I'll prolly hit up Summit Racing as their an fittings are a tad less expensive and guaranteed. Ever get around to the N249 and evap delete DIY?
 
#18 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

And here I thought it was one piece. Ha! I'll prolly hit up Summit Racing as their an fittings are a tad less expensive and guaranteed. Ever get around to the N249 and evap delete DIY?
yeah i deleted it all ... i gotta finish editing it into this one
 
#19 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

BTW just a lil hint from my expierence tonight ... what ever size vac caps u use under the manifold keep a few spares ... i had both of mine under the intake manifold crack and tear i guess from all the heat .... whenever i would put it in neutral like at a stop light the boost gauge would go to 8 or 12 on the vac side instead of the usual 20-22 where mine stays .... replaced the caps and it idles fine now
 
#20 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

If you can find them locally there should be a machinist store with High Temp Silicone Caps somewhere around you. I found a few places online but all want large quanities. The other option is 2 clamps, a bolt, and fuel line cut short and clamped tight. Those won't die out after a few months.

Or..... Just get a new High Flow Intake Manifold and plug the extra Vacuum -an threaded ports.
 
#24 ·
thanks for the quick reply
No problems .. A buddy of mine is a eurojet dealer if u want i can text him and see what kinda price he can get one to u for ... Continue this in a pm ... Dont like clutter in my DIYs

Sent From Mah iPhone4 Using Teh Tapatalk B!tches
 
#25 · (Edited)
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

I'm not exactly to sure what you are doing here sorry. do i need to buy this or just the two listed above? also i wanted to double check that doing both these procedures won't cause my MIL/CEL to come on, i already have no cat and passed emissions in CT, don't want to push my luck with a light lol.

still these stupid hoses are brittle from the heat and 167k and I'm not about to spend 150+60++++ for the hoses, rather catch it if I'm spending that much. thanks

also where did you get your plugs please or did you make them

V/r
 
#26 ·
Re: MKIV GTI/GLI 1.8T PCV Delete/Catch Can Install & Brake Booster Mod

I'm not exactly to sure what you are doing here sorry. do i need to buy this or just the two listed above? also i wanted to double check that doing both these procedures won't cause my MIL/CEL to come on, i already have no cat and passed emissions in CT, don't want to push my luck with a light lol.

still these stupid hoses are brittle from the heat and 167k and I'm not about to spend 150+60++++ for the hoses, rather catch it if I'm spending that much. thanks

also where did you get your plugs please or did you make them

V/r
the catch can and brake boosted mods wont throw any CELs or change any of ur emissions ... its just getting rid of unnecessary extra lines that could dryrot and cause leaks ..... not if u do the rest of the emissions controls delete stuff you probably will get a cel unless u get a custom tune like i did