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PCV Overhaul with 034motorsport PCV Kit (B5.5 AWM)

4.3K views 10 replies 3 participants last post by  VAGguy  
#1 ·
I have spent hours researching answers to my questions so I hope somebody out there has done the PCV overhaul with the 034 Motorsport PCV kit. I have a 2003 awm engine and without instructions when you receive the kit you wonder what you're supposed to do with the two black rubber stoppers. After many hours I have finally installed the main lower silicone hose replacing the old brittle dog bone. I have pictures at the bottom of this of the kit I'm referring to. There is a small bent tube that I'm supposed to connect to the main lower silicone hose at the PCV. My question is what does that small hose connect to? I was assuming it would connect to the SJP but I don't see how. I would like to know where to put these rubber stoppers and I don't know why no one ever posted pictures of them. I have a few pictures below but I also have a video on YouTube which explains my predicament better. Has anyone done this job? I have scoured the forums for hours and have found no answer.
YouTube video:

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Center of photo shows PCV sticking out of the lower main hose

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Small bent hose I'm supposed to attach to PCV and I don't know where else

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Center photo is SJP contraption small elbow tube would connect to valve cover not sure what to do with check valve that is to the left of the SJP

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#2 ·
I bought that kit and installed in on our 2005 Wagon (AWM) 5 or 6 years ago and I never did use/find a home for these two little thngs below (Assuming that's what you are asking about)..
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I guessed that they were for the AMB engine code?
 
#3 ·
The vacuum cap goes on the port at the back of the valve cover because the replacement bleeder valve does not have the side port that leads up to the valve cover.

The other is a plug, I think. I never used the plug.
 
#5 ·
Looking further at the etka diagram, I am wondering if I put the second small silicone hose that came in my kit to the small branch off the SJP . As the etka diagram shows it is connected to crankcase ventilation. My car is half an hour away sitting at my mechanics yard so I can't look into it at the moment.
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#6 · (Edited)
That Bentley diagram is not correct for the later AWM engines. The 034 kit replaces #6A for the old style bleeder valve without the side port #6. That also eliminates the hose/check valve assembly #24 which in 2003+ connected to that little port at the back of the valve cover.

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#7 ·
Oh yeah that makes more sense. I could barely follow that other diagram. So the bleeder valve is the PCV...
So in that diagram you have there, number 10 breather hose is equivalent to the short hose I've been asking about which still no one has confirmed that I should attach to the small branch on the SJP... I still can't believe no one has any pictures or video of this actual install on a 2003 awm... So I hope this helps somebody else. And I hope to get this back together. It's a total mess all disconnected and I'm just getting more confused.
 
#8 ·
I'll get under my hood in a few and snap some pics for you.
 
#9 · (Edited)
Vacuum cap on valve cover
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Top connection on intake manifold with the OEM clamp is the L hose that leads to the SJP. #10 connection is just underneath that. New hose from 034 connects to new billet bleeder valve.
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The connection in your video at time stamp :43 from the SJP connects to a small metal tube #69 that runs across the back of the motor, around the pass side of the motor #73 and terminates at hose #75 which connects to the turbo inlet hose #77. It cannot be deleted. I know the below chart for the SJP routing is really busy, but just follow the flow.
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This thread below links to my google drive which contains all the ETKA files and service manual, plus other good to have documents I have accumulated over the past 17 years of ownership. Save all you want.

 
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#11 ·
#10 connects to the intake manifold on a port about 1/4" under the hose in my second picture with the OEM clamp on it. Just look for it and it will be there. It connects the intake manifold to the bleeder valve.