WAG 1 8 T Tuning

8/2/2019 WAG 1 8 T Tuning

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2/28

SAI. N249" PCV, EVAP Removal Kit

lhis gu~dewill'l help you inistalll'the ccmporentstn the Kit. I ih:8veincluded elements ofthe AWD and AWP motors for the removal, In those cases you willi see the pag:e labeledspecifiicailly for tihe Awe or AWP. Thiis !Qiuideis ~nno way perfect, but it you havequestions or need help. send me an emaril: : nathans,[email protected]

Tif1I,enext two pages are th;e vacuum diiagrams for the AWP and AWO engil1lies..
mailto:nathans,[email protected]:nathans,[email protected]


3/28

9

t10


4/28

Start by removing y O ' l J I r eng: inecovers.


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6/28

un ba.ck Ihe bracket ..you wi!11need to cut 4ltnes,

Unsc l~ew~he ' ,c 'Q to l a li 1 ' t :b , I , U U id'~O Il'ieUS iVepressure lnthesys te 'm, . I lf 'tllle e 'ng ine! is hot,u n c r e w V t e r ) ' SilowilY , a ]IoWl inglth e 'P ressu re, to rel!e I8,se,glrad'uall~y


7/28

Wilg;glethe sensor and p'LIll:1pto remove lit You wiil.[lllose somecoolant. lfound itbest to ptaeea,couple of towels under thesensor area to catch most of It.


8/28

Remove the damps holding: ~h:e3 hoses Ito '~l1:ecoolant.neck. ihere ~sone onea.chside, as well as one underneath"You wi!l!llosesome more coolant here,ag!a~n,the towels ih:eilpm~nim~zethemess"

IRem,Qve the 2 fasteners holdwng th e coolant neck in[place. some cars use 10mm nuts, some cars use51i1l1mllen bolts. The second fastener is on (h,e lowerrig:ht of the neck indicated by Ihe second arrow,


9/28

Remove ~he S,AIhose

RemQvetihe hoses from the cootantmeek, and [putlit. out

'.

Now its time to remove the combl valve. Thereare 35mm allen pons ho.ldiing it in.


10/28

Tihlis tis aAWP eombl andhardil'ines

There are also 2 annoyingwire clips for the con packharness, they can be, pryedout wr~haf~at'head,"

.AWC Engi .neI 1'I"I,enarounes on a AWU are not mreclIry

eonaeeted to th:e combt, There Is anaddilonal boU holdlng ti t iin"


11/28

Once th!e combtIs removed,clean up thiesurt'ace area

Block pll!ategoes here ..lnstaHusing a 5nrm allen wrench.


12/28

Now Ilisa good tim e to rep:l!ace th e coolan t neck,expec~811 ly iif ~th 18 Sn ev er been done be fo r e . . l ln . st a li ll

u s in g t h e 5 1 l 1 i 1 ma .1 !lenw rench Rec:on 'l1 l.e ct h oses, andla :c e ~ h :e !j back on,


13/28

Awe Engiine

.AWP E n:g in e Cap this, port off;~ius,tpick one that fiits...

N.ow iit's time to remove the intakemaniiifo~ld.lhis makes ~h:eprocessextrem elY ea sy ..Start by undipwng anidreinoviing these 2 vac tines ..


14/28


15/28

Slide the willre cover dow 1 1 1 1 and up to remove it. You Inow have access to the 2 bolts hOldiing the fuel rail totheiinta.ke manIfold. Remove these 2 boUs so that thefuell raill can be moved out of ~heway for the intakemani.fold removal.


16/28

once the fuel ralteotts a re remo ve d, t U f t up onl1ih:e rai.ltoremove it just enough] to get to the l11a:nifo ld bo!lits,.

are 8 aJlienootts and 2 nuts hOilding thein taKe man ifo ld on. IR em o ve th em .


17/28

Niowthat the manifold is removed, you get a better pteture of the stuffthatneeds to be removed.Remove the "Y"shapedlIJne thatruns to 'the "Hloc:key Puck" andth e v a liv e c ov er"


18/28

Once alii of ,hie vac Ilines are removed, Iy ou s.h ou ld l be left wI~h the eilibow cOl11inglo ff th e to p o f Um ieo ~1c oo le r hOllisiing,,,Bethat the reducer iis stiU connected as'


19/28

ThiilSconnectorwllllead tothe Inlet of your catch can

Tillis .is the whatth.e line in thekit shou!lid .Iook like when n~sins,talled.

ThIs OOswhe r e you wi:lll attach th esupplied 5/8" hose, thilS wiil.1go to thecatch ean's inlet You wU[lrneed to cutthe appropriate amount of IIIInedepe:ncli ing on where you p!lace yourcatch can.


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21/28

tile c ov er 'is rem ov ed " [ I O O . kup an d to U 1,eeft: o f me w:heel !well . 'The "b~lue balls" are Ihelld inU lslin g 2 Bmm n uts. R em o ve~and you should be able top ulll th em riig ht o ut.


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23/28

Behiiind the (ool'ant ballIllwhere yOUCUit~hle black rubber band, YO'lJwiii l : l see 4lines gioing down iinto a black__ox,Remove the two closest 'to the coolantball. CO NO 'TREMO 'VE 'T iHE!moC L.O SES 'fTO TH _c W IINICSIHI I IELO..

Y o u w I:1 11e left: w ~th 2 . p la st ic ~ in esstickIngl up. Use the lnclludedvacuum caps to cap them off.Secure with a JlJ1inliclamp inclu:d.e'd iinthe kit"


24/28

N.owto remove the SAi l !pump.ihere will be 3 8mm aHen bo lts,h,o. ld ! i : I1Qltlin.l was able to g :et a lI I 3U1s! lnga ratcneo extenston commqfrom the top of the engline.IHowever" remove them an y w ayyou see ftt,

IRemove the "iHockeyPuck'!


25/28

appr())!Jmately 5 ft lbsof torque om the nuts andbolts. N,ow ts also a ,good time to replace themanifold ga:sk,etw'ith ll eit her ,astock one or aN'ewSouth Power G,asket. InslallaUoliI is reverseof remove];

SHleSO]fme naranne Ulat runs unaerthe fuel line. This lin,eIs not used

In:stall bolts Capthis off

I I F u e l R,ai l boltsPlug: theharnesses back in

Bolt under the lfl1:anifold

Rep:lace 0~1.ube If yOU! haven'tdone so al ready,

Cap off a : n l Y ' unused vacuum ports"


26/28

Us~ng the sUippliiedl1f2" vacline, and two hose clamps!connect ,hie ,I;arg;eport onthe intake manifold to thebrake booster check valve,, You may need to shorten'~helength Udesired. thereis a few extra inches thanneeded 0 1 1 1 1 ~heliil1le.

uSingl~h;ej,ncludeCl 5132" vac tine. run 'from youdiiverter to one or tne open [posts under ~heintakemanifold (cut the excess). Secure wmtha mlni clamp.

1II 1set he re ll fl aln iing 5/32" vac lin e, run a ,niew Illinefromyour f:u]e~pressure regulator to the second open post

For cars wi~h boost gaugies. use/reuse a"i"to run a llne to the gauge.


27/28

U:s!lngthe elbow slide of 'the 5/S" hose, connectto ~ii1 liep en en ,in g o n th e TlllPthat was le'ft ,b ythe "Hockey Puck"" secure w~tha,ctamp. Tlhle:other end connects to the catch can ouuet,

~t's resistor time! This next part wiilllbe J i l1UC:h more rellia:ble ifyouso'lder '~hew'ires to the resistor. however there are otherway,s of doinglit. Important thfng is~l1:atthe resistor "bridg:es"the wires and 'isprotected from the elements..You shouldhave 4 ! empty harnesses, two under ~heIntake mani,fo[d. onenear the ccotant balIl and one under ~hlecar near the o:iilfi:lter.

- -- --- --- -You will need to p l J I ! n back the pllas'tlc w ilre c :o ve ri:n go n th e harnesses toexpose the wires. I used a wire stripper to expose a section of each wire,sta ,g ,gered a s to a cc om od are th e srze o f 'Ih ie resisto r. so to er in :p la ce . W ra pth,e namess in elleclrlcall tape andlzip tile out of ttle way ..Do tnts forall4L


28/28

Final steps:' F il il lcootla:mtreservoir w ith 0,1 2

.'Start car a!ndlilletit runJ,it may run a.[Iittiled!ifferent for a 'few moments, but willI clear up soon- Shut car down. check coolant reservoir. most I'ilkel),"you wn~1need to a.dd 'more

R e-sta rttil1 l,e c ar a nd c neek fo r [Ileaks- If you have VagCom j clear any codes 'You have

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WAG 1 8 T Tuning