Helicoil stripped plastic valve cover threads.

[mtroxel]

OK, so it's not a true helicoil, but it's the same idea. It leaves a new, stronger set of threads in a stripped out plastic socket. On the 2.0T, the PCV fastens to the valve cover with nothing but fragile plastic threads. One of mine was completely gone and I was getting lots of intake air leak codes.

Tools you'll need? Not much.

Flat screwdriver
13/64" drill bit
small vice grips
- and -

A brass wood nut and a machine bolt that matches its threads such as this:



Not hard to find. Got the above one at the corner hardware store. You can get them at woodworking stores too.

The brass nut I used wanted me to drill an 11/64" hole. That might be good in wood, but the plastic is too hard for that so I used 13/64ths drill bit. Was too lazy to pull off the coolant tube so I just turned it with a small pair of vice grips.



After you have the hole enlarged and cleaned out, screw in the brass wood nut. The little slot you use to drive the brass with a screw driver will break off. It did on both the ones I tried. But you'll get it in far enough to have more holding power than the plastic threads Mr. Audi designed. If you have to, put a jam nut on your 6/32 and use that to drive the brass in all the way.



After you break off the rest of the brass that broke off, chase the threads with your 6/32 to clean them up.



I ended up putting more torque on this than on the other screws Mr. Audi designed. You get a very good hold.

[Denio24]

OK, so it's not a true helicoil, but it's the same idea. It leaves a new, stronger set of threads in a stripped out plastic socket. On the 2.0T, the PCV fastens to the valve cover with nothing but fragile plastic threads. One of mine was completely gone and I was getting lots of intake air leak codes.

What size threaded insert did you use? I'm going to tackle this today.

[mtroxel]

What size threaded insert did you use?

Not positive. What I do know is that I ended up with a 6/32 bolt. It is now 10 months later, and I've had no air leak errors since I did this. If it helps any, I ended up with 6/32 threads and the package on the insert wanted me to drill an 11/64" hole. I did but it was too tight for that hard plastic so I went up to 13/64".

[Denio24]

so the 11/64 is probably the diameter without the threads sticking out of the sides. Did you buy them at any major stores? my local ace didn't have any.

[mtroxel]

Did you buy them at any major stores? my local ace didn't have any.

Got mine at the local Ace Hdwr. I guarantee you Rockler Woodworking has them if you have any of those around there.

[thenofjboy]

good idea!!! the same hole on my PCV stripped. DEF gotta try this!