How To Replace The PCV Crankcase Vent Valve On A 2006 B6 VW Passat 2.0 T (008583 - Bank 1; System too Lean at Idle, 008825 - Leak in Air Intake System)

One morning when I started my passat, the engine started shuddering at idle like it was trying not to choke. When I drove I couldn't really feel anything, but it was very obvious during idle. Then the CEL (Check Engine Light) came on, so I scanned the car with VAG-COM by Ross-Tech and the following fault codes listed below where displayed on the report.


CRANKCASE VENT VALVE (PCV VALVE)


















Fault Codes:

Address 01: Engine Labels: 06F-907-115-AXX.lbl
Control Module Part Number: 3C0 907 115 F HW: 3C0 907 115 F
Component and/or Version: 2.0l R4/4V TFSI 0030
Software Coding: 0404010A19070160
Work Shop Code: WSC 05089 444 84564
VCID: 234F829E9B45
9 Faults Found:

008583 - Bank 1; System too Lean at Idle
P2187 - 004 - No Signal/Communication - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100100
Fault Priority: 0
Fault Frequency: 18
Mileage: 84055 km
Time Indication: 0
Date: 2011.09.19
Time: 13:59:26

Freeze Frame:
RPM: 890 /min
Load: 19.6 %
Speed: 0.0 km/h
Temperature: 78.0°C
Temperature: 54.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 13.589 V

008825 - Leak in Air Intake System
P2279 - 002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 5
Mileage: 84071 km
Time Indication: 0
Date: 2011.09.19
Time: 15:27:57

Freeze Frame:
RPM: 856 /min
Load: 16.1 %
Speed: 0.0 km/h
Temperature: 87.0°C
Temperature: 68.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 13.208 V

000665 - Boost Pressure Regulation: Control Range Not Reached
P0299 - 002 - Lower Limit Exceeded - MIL ON
Freeze Frame:
Fault Status: 11100010
Fault Priority: 0
Fault Frequency: 1
Mileage: 84132 km
Time Indication: 0
Date: 2011.09.20
Time: 12:37:50

Freeze Frame:
RPM: 2826 /min
Load: 78.8 %
Speed: 81.0 km/h
Temperature: 77.0°C
Temperature: 41.0°C
Absolute Pres.: 1010.0 mbar
Voltage: 13.716 V

000768 - Random/Multiple Cylinder Misfire Detected
P0300 - 002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 6
Mileage: 84438 km
Time Indication: 0
Date: 2011.09.20
Time: 20:14:22

Freeze Frame:
RPM: 817 /min
Load: 14.5 %
Speed: 0.0 km/h
Temperature: 81.0°C
Temperature: 61.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 13.589 V

000771 - Cylinder 3: Misfire Detected
P0303 - 002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 6
Mileage: 84438 km
Time Indication: 0
Date: 2011.09.20
Time: 20:15:17

Freeze Frame:
RPM: 841 /min
Load: 14.9 %
Speed: 0.0 km/h
Temperature: 82.0°C
Temperature: 63.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 13.335 V

000772 - Cylinder 4: Misfire Detected
P0304 - 002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 6
Mileage: 84438 km
Time Indication: 0
Date: 2011.09.20
Time: 20:15:17

Freeze Frame:
RPM: 841 /min
Load: 14.9 %
Speed: 0.0 km/h
Temperature: 82.0°C
Temperature: 63.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 13.335 V

000770 - Cylinder 2: Misfire Detected
P0302 - 002 - Lower Limit Exceeded - Intermittent
Freeze Frame:
Fault Status: 00100010
Fault Priority: 0
Fault Frequency: 5
Mileage: 84438 km
Time Indication: 0
Date: 2011.09.20
Time: 20:15:17

Freeze Frame:
RPM: 841 /min
Load: 14.9 %
Speed: 0.0 km/h
Temperature: 82.0°C
Temperature: 63.0°C
Absolute Pres.: 1000.0 mbar
Voltage: 13.335 V

000769 - Cylinder 1: Misfire Detected
P0301 - 008 - Implausible Signal - Intermittent
Freeze Frame:
Fault Status: 00101000
Fault Priority: 0
Fault Frequency: 2
Mileage: 84517 km
Time Indication: 0
Date: 2011.09.20
Time: 23:16:07

Freeze Frame:
RPM: 1779 /min
Load: 31.4 %
Speed: 34.0 km/h
Temperature: 84.0°C
Temperature: 57.0°C
Absolute Pres.: 1010.0 mbar
Voltage: 13.716 V



So after doing a lot of research, I found out that the Crankcase Vent Valve might be the cause of all these faults, and due to the leak in the intake, the cylinders are misfiring. One way to check if the Crankcase vent valve is faulty, is to start the engine and try to remove the engine Oil cap, and due to the very high suction, it is literally very hard to remove it. And that was the case with my car, I'm not saying its impossible to remove the oil cap while the engine is running, but you have to really pull on it to remove it compared to the normal situation where it comes off easy. Below are pictures and DIY steps for replacing the Crankcase vent valve.




STEP 1

Remove the plasic Silver Engine cover and locate the Crankcase Vent Valve to the right of the engine oil cap.
















STEP 2

Remove the 2 hoses that attach to the Crankcase Vent Valve by carefully pressing on the lock rings that fasten them and pulling them back.




















STEP 3

Unscrew the 4 screws that attach the Crankcase Vent Valve to the enginge.
















STEP 4

This is the Crankcase Vent Valve Gasket. Pay special attention to the little tail at the bottom of the right ring. This is there for a reason, so the gasket is not installed upside down. This Gasket costs about $45 and the next question is "Does it need to be replaced?". Well, it is always best to replace with a new one, but in this case, you don't need to replace it if it is not damaged.
















STEP 5

If you decide on replacing the old Crankcase Vent Valve Gasket, then make sure you clean the grooves that it fits in with a cloth and thin screwdriver from any scum or residue.






















STEP 6

When installing the new Crankcase Vent Valve Gasket, pay special attention to the tail on the bottom of the right ring, and snuggly fit the gasket into the groove.
















STEP 7

After carefully checking that the gasket is in place, attach the new Crankcase Vent Valve and fasten it with the 4 screws. Be very careful when tightening the screws, so you don't over tighten and damage the Crankcase Vent Valve. It is a plastic part and can crack. Then attach the the inner hose first and make sure it locks into position.
















STEP 8

Attach the second hose and also make sure it locks into position. Then do a final check to make sure everything is connected properly and attach the silver engine cover.

STEP 9

Now reset the fault codes using VAG-COM and start the engine. Even if you start the engine before reseting the fault codes, you will definitely feel a big change in engine performance immediately. The CEL will not turn off by itself, so you will definitely need to use VAG-COM to turn it off.