Create A PCV Valve Bypass System


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{mosgoogle}Mark the spot where the hose ends will bend down to, and then cut the metal hose ½" longer than that mark.  In other words, extend you marks ½" toward where the fuel filter will inserted into the line.  Use either a pipe cutter (preferred), or a hack saw.

If you use a hacksaw, you MUST REMOVE ANY AND ALL FILINGS FROM THE LINE!!!  After you cut the metal line, use a file to smooth it out a little.  A small Philips screwdriver can be used to help round out the metal hose again.  Use brake cleaner, pipe cleaners or even string to help remove any debris in the hose.  Blowing into one end until you see spots will help too!  Connect the ends of the fuel hose to the ends of the metal hose and use the remaining two clamp to secure them.  Remember to use a little motor oil to aid in seating the hose ends properly.

This is how it should look when you are done:

Filter Placement

You’re almost done with the fabrication now.  If your old rubber hoses were pretty rotten, you can take the remaining three inches of hose and replace the manifold end and the PCV Valve end with it.  Cut the remaining piece of fuel line into a one inch and two inch pieces.  Put the two-inch piece of hose onto the end of the metal hose that goes into the manifold.  This will give you some flexibility when positioning the fuel filter.  Put the one-inch piece of hose onto the end where the PCV Valve will be attached.  No clamps are needed, and besides, you don’t have any more!

Now use you zip ties to secure the fuel filter to the wiring harnesses behind it.  Zip tie locations should be a few inches away from the ends of the filter so as to allow you to unscrew one end of the filter for changing out the filter in the fuel filter housing, noted by the yellow arrows in the last picture below:

Complete PCV System

Recheck that all of your connections are secure.  This is a metered system and you don’t want any leaks even though the pressure running through this system is very small!  Make sure that you check the fuel filter every time you change you Mustang’s oil and inspect it for excessive oil build up or puddeling.

Categories: Mustang Tech

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