Transcript
Engineered For Performance 2.0T FSI PCV Bypass / Oil Catch Tank Kit Applications: Transverse and Longitudinal 2.0T FSI only (Not applicable to newer TSI / TFSI engines)
Tools Required: T25 Torx drive bit 7mm socket Flat-head screwdriver 3mm and 5mm Allen wrench or drive bit Blue colored, medium strength, Loc-Tite liquid thread locker. Protective eye-wear and gloves are also recommended Please thoroughly read through and familiarize yourself with these instructions in their entirety prior to beginning the installation process of any component. Please also ensure that the vehicle and engine have cooled down sufficiently to avoid risking skin burns or other injury. - If the vehicle is equipped with the OEM engine cover / airbox assembly, it will need to be removed to facilitate this installation. You will need to disconnect the two clips that secure the turbo inlet hose at the top left of the cover just to the left of the MAF sensor connection. Pull this hose out of its connection to the cover. Also disconnect the electrical connector for the MAF sensor. At the front of the cover, you can remove the clamp that secures the cover to the corrugated inlet hose or unclip the inlet hose from the front inlet duct. Firmly grasp the corners of the cover and lift up to remove the cover from the plastic posts on top of the engine. Once removed, you should have clear access to the OEM PCV assembly.
First unclip the connectors for both ends the corrugated plastic hose that connects the PCV to the intake manifold. Pinch down on the knurled clips at the end of the hose and simply pull out the hose connectors. Next, using the T25 Torx bit, remove the 4 screws securing the PCV assembly to the valve cover. Save these screws as they will be re-used later.
Next, very carefully use a flathead screwdriver to unclip the connector on the extreme right end of the PCV assembly. This connector secures at the top and bottom and both sides, so all 4 clips must be undone. Again, please exercise caution as this piece is very delicate. Do not break these clips otherwise you will need to replace the entire hose.
With the OEM PCV assembly removed, inspect the orange rubber gasket/seal and wipe away any excess oil from around the flange. Secure the black anodized replacement Forge PCV bypass plate using OEM screws removed previously. Secure them just tight enough to tightly sandwich the orange rubber gasket/seal so that it cannot be seen from behind the Forge plate. Please be careful not to over tighten these screws as they are threaded into the plastic valve cover and over tightening may strip the threads in the valve cover. Also reattach the previously disconnected clip connector into the far right hand connection on the replacement Forge plate until the clip locks in place firmly.
Next you will need to mount the tank in the location of your choosing. We have created a universal bracket setup that should accommodate most locations by allowing you to swivel, rotate, and modify the position of the bracket on the tank to suit your needs, however, for the transverse 2.0T applications, we suggest using the small threaded hole just between the motor mount and A/C hard line. Use the included 5mm Allen bolt (M6x1.0 thread pitch) and washer to secure the tank to this location or use your own supplied hardware if you wish to select a different mounting location.
With the PCV bypass plate and tank mounted, you will now need to connect them with the supplied hoses. From a functional standpoint, either fitting on the tank can be utilized as the inlet or outlet, however, the simplest routing of the hoses is achieved by connecting the right fitting on the plate to the forward fitting on the tank, and the left fitting on the plate to the rear fitting on the tank as shown below. Secure all hose connections with the supplied hose clamps.
If the hoses are too long for your liking, they can be trimmed to suit your needs or desired tank mounting location. We recommend cutting the hoses with a new razor blade or box cutter. You may also wish to secure the hoses together with some plastic zip ties to keep them routed together and prevent any slack from interfering with the reinstallation of the engine cover or any other modifications you may have undertaken.
The last step is to install the clip-on blanking cap for the intake manifold. Prior to doing so, however, you must first select how many of the 3 available pressure/vacuum references you need to utilize, and for what accessories. The three provided vacuum nipples have different size holes to suit different needs. - The nipple with the smallest hole should be used for a boost gauge - The nipple with the largest hole should be used for a mechanical DV reference - The nipple with the middle size hole should be used for a water/meth injection reference or other accessory −
Any unused references on the cap must be plugged with the supplied grub screws. (3mm allen) It is highly recommended that all vacuum nipples and port plugs are secured with blue colored, medium strength, semi permanent Loc-Tite liquid thread locker. If not used, the nipples and plugs may not be secure enough and may back out under pressure creating a boost/vacuum leak. When threading the nipples into the cap, you may wish you use a small piece of vacuum tubing or some other non-slip material to slip over the vacuum nipple in order to get a better “grip” on it when tightening it. To install the manifold cap, you will slide the cap over the barb on the intake manifold until the lip of the barb can no longer been seen through the grooves on the cap. The double o-ring seals are very tight and secure so this may take a bit of effort. Once the lip of the barb is no longer visible, insert the black plastic C-clip to secure the cap in place.
If you already have or plan to use our full replacement diverter valve in conjunction with this catch tank kit, this cap will need to be used in place of the manifold tap supplied with the replacement diverter valve. If you require the use of more than 3 vacuum/pressure references, however, you will need to stack this cap on top of the manifold cap.
This catch tank is supplied with a sight glass on the side so that you can monitor the fluid fill level in lieu of performing periodic draining of the tank via the incorporated drain plug at the bottom of the tank. Drain intervals will vary based on the amount of fluid collected. This will depend heavily on the amount of blow-by gasses of the vehicle in question, how much the vehicle is driven, and ambient environmental conditions (temperature). More fluid will be collected in the tank in cooler temperatures compared to warmer weather.
As always, with any questions or concerns about this product, please feel free to contact your local or preferred Forge Motorsport dealer/installer, or you may contact us directly. Forge Motorsport US (407) 447-5363 /
[email protected] Forge Motorsport UK (+ 44) 1 452 380 999 /
[email protected]
