Well I just finished getting rid of all the “unneeded” check valves, vacuum lines and PCV system. There is now a lot more room to work with….valve cover gasket is about a 10 minute job, and the coolant flange is 15 minutes top!
Honestly, you could go ahead and follow this DIY and just rid yourself of the lines/valves, but I would HIGHLY recommend you read the following two links (in order) so you can gain a better understanding of the system, how it works, and where to look if something goes wrong.
(Most of thread is bits here and there, but mainly pages 3-5)
After reading all that, lets proceed with the pics! (Then again you read those two links fully, so you should be able to do this blindfolded……right? )
Unfortunately all pics were taken with my Blackjack 2
First and foremost, make yourself very familiar with this picture and its terms and the general idea of how the vacuum lines will look like after it is all said and done: (Thanks to Daniel (b6lovin) for this beautiful diagram and his help )
Time to start tearing your car apart!
Remove air snorkel and airbox:
PCV system removal
Remove plastic cover and ignition coil harness (don’t forget to unbolt that 10mm bolt in-between coilpack 1&2)
Now we will remove the PCV breather tube:
Loosen the hose clamp that is circled
Remove the 3 hex bolts that attach the breather tube to the valve cover (the third hex bolt can be seen in the next pic)
Loosen the three crankcase breather hose clamps that are circled (the third hose clamp can be seen in the next pic)
EGR/SAI system removal
Next we will be removing the EGR valve and its breather tube (for this you will have to have the Integrated Engineering block off plate. I would recommend you get it through Apex Tuning - great customer service )
Remove the one-time-use hose clamp that is circled and also unbolt the three 5mm hex bolts that are in-between the head and firewall)
Remove the two 10mm bolts that are circled
Next remove the hose clamp at the end of that tube (near the TIP) and remove the whole tube
The EGR valve will also be removed at that same time and here is a better pic of how those three 5mm hex bolts are configured
At this point this is how it should all look
Now we will be installing that Integrated Engineering block off plate in place of the EGR valve
Just bolt it in place with the supplied bolts (make sure that the supplied o-ring is also in its place)
Now we are removing the secondary air pump. Remove the two plastic lines that are connected to the pump
Unclip the harness and unbolt the three bolts
With all that out the way you can now unbolt the air pump bracket. There are three 10mm bolts (one from under car and two from up top)
Now lets remove this tube
The are two 5mm hex bolts that hold it to the turbo (one from up top and one from underneath - the bolts are adjacent to one another)
Lets finish off with the passenger side, so let remove the hose clamp from the pancake valve and the plug up thr TIP.
I temporarily plugged it with this
Now we must plug one more line on the TIP (it is the line that ran off of the bottom of the airbox)….(disregard the bottom half of the picture…it does refer to the step just mentioned above though.)