How-To: GM 1.4L LUV/LUJ PCV Fix Kit V2 Install

Overview:
For details and ordering information on the PCV Fix kits, go to: Welcome to CruzeKits.com - Home of the PCV Fix Kit

Note: This PCV fix kit has been replaced by the V2.1 PCV Fix kit, which uses a EVAP purge line "Y" fitting for a vacuum source instead of the brake booster tee.


Tools Required:

• A step bit that can drill down to 9/16" (Available on Amazon.com) - I got a set of 3 at Menard's for $12
• A cordless drill
• 2 adjustable wrenches
• Pipe thread sealant (teflon tape would also work)
• A file
• An Allen wrench set
• A #2 phillips screwdriver witha 6"+ shaft, or a screwdriver with interchangeable bits and an extension that can get you the same length (this will be needed to install the plug)
• A GOOD, strong degreaser that leaves no residue. Brake clean may work.
• A plastic brush (an old toothbrush will work)
• A hole punch
• A hammer
• A flathead screwdriver or comparable tool to mix and apply epoxy
• A paper towel to wipe the epoxy off the applicator tool
• In-lb torque wrench (Available on Amazon.com)

Note: these are only the tools that will be required to install this fix. You will need other tools to get the intake manifold off.


Parts Required:
- PCV Fix Kit V2

DISCLAIMER:
This solution has been tested, proven, and is generally considered reliable. To ensure a proper install, MAKE SURE YOU READ AND UNDERSTAND EVERYTHING IN THIS POST. Neither I nor CruzeTalk.com accept any liability for what happens during or after the installation of this kit. Proceed at your own risk. This is a kit that is being offered for your convenience. It is your responsibility to ensure that the components are working correctly and remain in good operating condition to prevent any issues. It is your repsonsibility to ensure that the components are clean (such as the check valve and the brake booster tee fitting on the V2 kit) and in working order to ensure there are no potential issues down the road. For full disclaimer: click here.

Procedure:
Note: if you've never worked with NPT fittings before, just remember; you can keep tightening, but you should not back out unless you're disconnecting and re-connecting (with new thread sealer). Also note: don't be afraid to use a lot of sealant tape. You should be making at least 5 laps around the threads with the tape.

1. Remove intake manifold from vehicle, and remove throttle body from manifold. Tutorial for removing the intake manifold can be found here: How-To: Remove 2011-2016 Cruze 1.4L Intake Manifold

2. Using degreaser and a toothbrush, thoroughly clean and de-grease the original check valve openings, surrounding area, and a few inches into the bottom of the PCV port (the flat area). The original PCV opening must be free from any contaminants and must be bone dry in order for the epoxy to adhere permanently. If using a strong solvent like brake clean, I'd recommend removing the gasket surrounding the ports first. Make sure the PCV port is dry before proceeding.



3. Below is where you will be installing the screw and washer. The idea is that if your check valve is missing that hole needs to be plugged up as it's creating a boost leak. First, drive the screw half way into the center hole for the check valve dry (without any epoxy) to start the thread, then back out.




4. Place the washer over the screw, and liberally coat the screw thread with epoxy. The more you can pile on there, the better. Have at least as much as shown below, more if possible.



5. Next, carefully, being sure not to touch the walls, drive the screw back into the hole all the way to the end. Once the screw starts drilling itself in, it will start to go in straight. IMPORTANT NOTE: don't over-tighten the screw.

6. Screw it in till it hits the end, then lightly tighten until it's snug. If you over-tighten, the screw will strip the plastic. This is just to hold the washer in place, the epoxy will do the sealing and holding.

7. At this point, the epoxy should have bonded to the screw, the washer, the surface of the port, and should have been pressed through the outer holes on the port to produce an excellent bond. However, if you want to more remaining epoxy on your mix surface, feel free to add around the screw for good measure. Once the epoxy cures, it's never coming off. Note: do not block off the port coming up out of the manifold that the corrugated hose connects to!



4. Be sure to wipe off the screwdriver you're using after every single application. That stuff dries fast and you'll be scraping it off later. Full cure takes 24 hours but if you start with this part first, you'll be fine getting the intake manifold back together and starting the car, since it will be dry to the touch within an hour. No need to wait overnight before you start up the car.

5. Flip the intake manifold upside down and place a washer centered on the flat side. Make sure it is centered horizontally. I'd recommend starting 1/4" or so further back than I did in this picture to give yourself some flexibility in case the hole gets too close while you're drilling. Use a hole punch and hammer to make an indentation where the thread will be starting. Note: as of January 2019, I've been shipping kits out with a larger flat washer for the outside; make sure you drill the hole a tad further back than needed to ensure the washer lays flat on the runner.



6. Using a step bit, slowly and carefully drill down to 9/16", being sure to keep it centered. If you have trouble getting it centered, you can try drilling a small 1/8" pilot hole with another drill bit first. Note that the hole on mine ended up a little too close to the opening. This is why I recommended you start further back to give you some flexibility in case this happens.




7. Using a file, file down two opposing edges of one washer until it slides through the PCV port opening. Do the same for two opposing edges of the locknut. This won't take much filing. Note, you may not have to do this if you have the newer style locknut.



8. Fit another un-modified washer over the NTP adapter, and fit the adapter trough the hole. Fit the nitrile gasket over the threads, followed by the washer you filed down.