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 Post subject: Dried/cracked PCV repair
PostPosted: Sat Jan 25, 2014 1:37 am 
In Neutral
Joined: Sun Jan 19, 2014 3:20 am
Posts: 4
94 Legacy Wagon, Turbo AWD, 197k mi.

OH what fun I'm having with dried out, hard, cracked PCV/vacuum system!
This adventure started with the newly acquired vehicle not passing emissions (high carbon monoxide, 400 of 200 allowable.)

O2 sensor was looking good in closed loop, but a mechanic recommended replacing it 'because it's lazy'. They recommended replacing the PCV valve due to smoking oil leak in the engine bay. Finally they wanted to replace both cats (saying one in the exhaust manifold under the engine, and second behind the turbo).

So I started replacing the PCV valve, the 'rubber' hose was cracked and broke. So I tried to get it off of the 'F pipe', which also broke. Basically everything rubber is breaking as I chase it down. I had to take the turbo inlet elbow off to access other piping, and it is cracked too!


So I'm getting bulk 1/2", 5/8", 3/4" rubber piping together from the local auto parts. I'm going to need to track down some Y adapters for those sizes. I'll also need to either replace the turbo inlet (I see these are available in Canada?), or cobble something custom with a silicone elbow and the 'coffee cup' mod.


So first let my story be a warning to others - lol.


Second, I'd love some advice on how people have been able to access the vertical vacuum port (PCV port?), on the top of the rear passenger side of the engine, beside the turbo. Images attached below.

Thanks in advance!


P.S. the Turbo to Throttle hose is hard as a rock - I cannot pull it off without damaging it. :(


Image

Image

Image

Image


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sat Jan 25, 2014 1:43 am 
In Neutral
Joined: Sun Jan 19, 2014 3:20 am
Posts: 4
P.P.S. HUGE thanks to VRG3 for the vacuum hose image you made, and PCV system image scanned from the manual. :)


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sat Jan 25, 2014 3:54 am 
Site Admin
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Joined: Tue Oct 15, 2002 11:37 am
Posts: 27100
Location: Houston, Tx
Welcome to the BBS!

Before you just go and replace the PCV hose with bulk rubber hose, I suggest reading this thread regarding using the proper emissions hose. Over time the radiator hose will swell and become soft.

As for getting that rear 3/4" hose off, long needle nose pliers to get the hose clamp off works best.

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Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
1997 Impreza OBS

If you need to get a hold of me please email me rather then pm


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sat Jan 25, 2014 8:43 pm 
Second Gear
Joined: Mon Oct 02, 2006 12:58 am
Posts: 367
Location: Bellingham WA
^^^ THIS IS IMPORTANT, I've had to replace a lot of heater core hose that has been used for PCV on friends and customers cars due to leaks, and it doesn't take long to do so!

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92 Legacy Turbo, 5sp MT, Early Large CC 20G heads, Ported custom clocked td04, Cobb catted DP, Injen SS 3" exhaust, Turbosmart MBC @ 10psi, Apexi 20g intake, custom FMIC, Fidanza 11lb flywheel, stock 05 WRX clutch


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sun Jan 26, 2014 2:12 am 
In Neutral
Joined: Sun Jan 19, 2014 3:20 am
Posts: 4
Thanks for the greetings :)

I got some 11" needle nose, and some long 'hose pliers' from harbor freight - the old hose is off!

Thanks for the tip on not using the heater hose - this job sucks and I only want to do it once! lol


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sun Jan 26, 2014 7:44 pm 
Fifth Gear
Joined: Fri Jun 20, 2008 8:17 am
Posts: 6202
Location: Lakewood, Wa 98439
If you haven't gotten everything off yet a good tool to have is a heat gun. Heating up the hoses before attempting to pull them off (charge pipe included) will make it less easier to crack or break the hose.

_________________
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Wed Feb 05, 2014 11:24 pm 
First Gear
Joined: Mon Dec 24, 2012 8:37 pm
Posts: 179
im having to replace the hole system with oem stuff the guy who owned my wagon before me had a bunch of the stuff broken and cracked and used a wrx cross over pipe for part of the system....


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Fri Feb 07, 2014 1:27 am 
Fourth Gear
Joined: Sun Jun 10, 2007 4:35 am
Posts: 1732
Location: All over the place
The tip about using a heat gun should be in one of the stickies. I went through the "breaking every PCV component I touched" phase like 5 years ago. I had a heat gun too, but it just never occured to me.

_________________
93 Touring Wagon (EJ20G 5spd Swap) -- In storage while I work (and never get to play) in JDM-land.
00 Forester S/tb (predecesor to the XT) -- My JDM fling, dont tell my Touring Wagon!


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Fri Feb 07, 2014 1:30 am 
Fifth Gear
Joined: Fri Jun 20, 2008 8:17 am
Posts: 6202
Location: Lakewood, Wa 98439
Yeah, heat gun helps so much.

Sent from my SGH-T889 using Tapatalk

_________________
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Thu Feb 13, 2014 8:29 pm 
Fourth Gear
Joined: Mon Oct 27, 2003 7:17 am
Posts: 1885
Location: Oahu, Hawaii, USA
So, on what heat setting do you use the heat gun? How much do you heat up the hose? Hot enough to wear an insulated glove before attempting to pull the hose off?

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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sun Feb 16, 2014 12:05 am 
Site Admin
Site Admin
Joined: Tue Oct 15, 2002 11:37 am
Posts: 27100
Location: Houston, Tx
All you're trying to do is heat the hose enough so it remains flexible. I would use the low heat setting, but will let others that have done it chime in.

_________________
Josh

surrealmirage.com/subaru
1990 Legacy (AWD, 6MT, & EJ22T Swap)
1997 Impreza OBS

If you need to get a hold of me please email me rather then pm


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sun Feb 16, 2014 5:53 pm 
Fifth Gear
Joined: Fri Jun 20, 2008 8:17 am
Posts: 6202
Location: Lakewood, Wa 98439
I've gotten away with the high heat setting on some stuff that is really hard like plastic. But mostly I use the low setting like Josh mentioned.

_________________
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sun Feb 16, 2014 9:54 pm 
Fourth Gear
Joined: Mon Oct 27, 2003 7:17 am
Posts: 1885
Location: Oahu, Hawaii, USA
Thanks for the feedback. Now, another question: After the hoses are softened enough to get them off, do they remain soft or do they become hard (or harder) again? I'm asking because I'm going to have to be removing some of those hardened hoses in my engine bay and I'd like to plan for what to expect. Thanks!

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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sun Feb 16, 2014 10:06 pm 
Fifth Gear
Joined: Fri Jun 20, 2008 8:17 am
Posts: 6202
Location: Lakewood, Wa 98439
They will harden after they cool off. They wont be harder than before. When you go to put them back on, you will want to soften them with the heat gun again.

Sent from my SGH-T889 using Tapatalk

_________________
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Sun Feb 16, 2014 11:14 pm 
Fourth Gear
Joined: Mon Oct 27, 2003 7:17 am
Posts: 1885
Location: Oahu, Hawaii, USA
Thanks, cj! I appreciate your input! :D

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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Mon Feb 17, 2014 12:12 am 
Fifth Gear
Joined: Fri Jun 20, 2008 8:17 am
Posts: 6202
Location: Lakewood, Wa 98439
Always happy to help!

Sent from my SGH-T889 using Tapatalk

_________________
91 L-TW Wagon with a full Swap -RIP
92 SS Prefaced, GD dash swapped, 22T/205 Hybrid 20 psi - BEAST!
93 SS Bone Stock Gone!
94 TW Bone Stock Gone!
91 SS 4EAT Sold!
98 LGT 4EAT
98 LGT Wagon 4EAT


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 Post subject: Re: Dried/cracked PCV repair
PostPosted: Thu Apr 24, 2014 3:18 pm 
First Gear
Joined: Thu Mar 08, 2012 12:37 pm
Posts: 219
Location: pdx
There's a hose labeled "fuel vapor use, not for fuel line". That's what I used.

Rotate it back and forth while wedging it on the direction of removal. I used a flat head screw driver as a wedge. You can use a pair of pliers to rotate it, but pinch away from fittings so you don't crush them in.

I add a couple drops of transmission fluid under the hose after "breaking it loose" by rotating if its really bad.


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