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PCV Valve Retrofit - AES Motor (1997-2000)


 

As many others have discovered, the PCV valve diaphragm for the AES motor fails most likely due to the harsh environment and/or age of the component. New replacements are essentially non-existent and crazy expensive if you find one. A used component, if you can find one, may fail in short order again given the age/construction of the component.

In my case, the PCV valve failed in two ways. First, the vacuum line/side of the PCV was compromised allowing the suction of engine gases into the intake manifold causing a lean condition. The computer compensated by adding more fuel to correct the lean condition as measured by the front O2 sensor. Gas mileage had suffered for some time and I was unable to track down the cause as there was no check engine light nor was there a noticeable drivability issue. The partial load/long term fuel trim was running at 12.5% which is well above the specification of -5 to +5%. I replaced the original O2 sensors (140k miles) as their response were a bit sluggish and thought it may be contributing to the problem but there was no improvement in fuel trim. I then replaced most of the vacuum lines which were in fair shape but not terrible. In replacing the vacuum line to the PCV valve, I happened to check the PCV operation by sucking on the vac line to it and found the vac diaphragm had failed. I then plugged off the vac line and nipple to the valve. Bingo, fuel trims corrected and ended up in the range of 0-1% and the idle seems slightly smoother.?

A further check of the PCV valve found that engine side diaphragm was also free flowing engine gases to the intake tube/throttle body in vacuum/load conditions which likely messes with the fuel trim in load conditions. Since replacement PCV valves are hard to come by, following is my fix that might be of interest to others.

I wanted a dependable quality made part that was easily serviceable and/or replaceable along with no modifications to the original configuration should a quality OE style part become available (highly unlikely). I settled on Toyota part #12204-20040 which fits various 3.0-3.3L engines from 2001-2006. It's compact, designed to be mounted horizontally, and for an engine approximately the same size as the 2.8L VR6. Here's some pics of my MacGyver configuration.

?






 

Nice work. Welcome to the world of the Cuban's!


On Mon, Apr 17, 2023 at 11:47?AM <rmartin1962@...> wrote:
As many others have discovered, the PCV valve diaphragm for the AES motor fails most likely due to the harsh environment and/or age of the component. New replacements are essentially non-existent and crazy expensive if you find one. A used component, if you can find one, may fail in short order again given the age/construction of the component.

In my case, the PCV valve failed in two ways. First, the vacuum line/side of the PCV was compromised allowing the suction of engine gases into the intake manifold causing a lean condition. The computer compensated by adding more fuel to correct the lean condition as measured by the front O2 sensor. Gas mileage had suffered for some time and I was unable to track down the cause as there was no check engine light nor was there a noticeable drivability issue. The partial load/long term fuel trim was running at 12.5% which is well above the specification of -5 to +5%. I replaced the original O2 sensors (140k miles) as their response were a bit sluggish and thought it may be contributing to the problem but there was no improvement in fuel trim. I then replaced most of the vacuum lines which were in fair shape but not terrible. In replacing the vacuum line to the PCV valve, I happened to check the PCV operation by sucking on the vac line to it and found the vac diaphragm had failed. I then plugged off the vac line and nipple to the valve. Bingo, fuel trims corrected and ended up in the range of 0-1% and the idle seems slightly smoother.?

A further check of the PCV valve found that engine side diaphragm was also free flowing engine gases to the intake tube/throttle body in vacuum/load conditions which likely messes with the fuel trim in load conditions. Since replacement PCV valves are hard to come by, following is my fix that might be of interest to others.

I wanted a dependable quality made part that was easily serviceable and/or replaceable along with no modifications to the original configuration should a quality OE style part become available (highly unlikely). I settled on Toyota part #12204-20040 which fits various 3.0-3.3L engines from 2001-2006. It's compact, designed to be mounted horizontally, and for an engine approximately the same size as the 2.8L VR6. Here's some pics of my MacGyver configuration.

?






 

RMartin1962 - thank you for this great report.

How does one measure the "partial load/long term fuel trim" ? I have VCSD Lite (and am willing to upgrade to the paid version).

Mike

The partial load/long term fuel trim was running at 12.5% which is well above the specification of -5 to +5%. I replaced the original O2 sensors (140k miles) as their response were a bit sluggish and thought it may be contributing to the problem but there was no improvement in fuel trim. I then replaced most of the vacuum lines which were in fair shape but not terrible. In replacing the vacuum line to the PCV valve, I happened to check the PCV operation by sucking on the vac line to it and found the vac diaphragm had failed. I then plugged off the vac line and nipple to the valve. Bingo, fuel trims corrected and ended up in the range of 0-1% and the idle seems slightly smoother.


 

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I am driving across the U.S. in my 1995 Eurovan 5 MT. My mileage per gallon fluctuates: mostly over 20, but as high as 34 and as low as 17. I’d say the van gets peckish at altitude and isn’t keen on chilly weather.?
If anyone could point me in the direction of what would incline this wonderful contraption to overachieve I’d be appreciative.?

Jay Dwight

On Apr 17, 2023, at 1:47 PM, rmartin1962@... wrote:

?As many others have discovered, the PCV valve diaphragm for the AES motor fails most likely due to the harsh environment and/or age of the component. New replacements are essentially non-existent and crazy expensive if you find one. A used component, if you can find one, may fail in short order again given the age/construction of the component.

In my case, the PCV valve failed in two ways. First, the vacuum line/side of the PCV was compromised allowing the suction of engine gases into the intake manifold causing a lean condition. The computer compensated by adding more fuel to correct the lean condition as measured by the front O2 sensor. Gas mileage had suffered for some time and I was unable to track down the cause as there was no check engine light nor was there a noticeable drivability issue. The partial load/long term fuel trim was running at 12.5% which is well above the specification of -5 to +5%. I replaced the original O2 sensors (140k miles) as their response were a bit sluggish and thought it may be contributing to the problem but there was no improvement in fuel trim. I then replaced most of the vacuum lines which were in fair shape but not terrible. In replacing the vacuum line to the PCV valve, I happened to check the PCV operation by sucking on the vac line to it and found the vac diaphragm had failed. I then plugged off the vac line and nipple to the valve. Bingo, fuel trims corrected and ended up in the range of 0-1% and the idle seems slightly smoother.?

A further check of the PCV valve found that engine side diaphragm was also free flowing engine gases to the intake tube/throttle body in vacuum/load conditions which likely messes with the fuel trim in load conditions. Since replacement PCV valves are hard to come by, following is my fix that might be of interest to others.

I wanted a dependable quality made part that was easily serviceable and/or replaceable along with no modifications to the original configuration should a quality OE style part become available (highly unlikely). I settled on Toyota part #12204-20040 which fits various 3.0-3.3L engines from 2001-2006. It's compact, designed to be mounted horizontally, and for an engine approximately the same size as the 2.8L VR6. Here's some pics of my MacGyver configuration.

?
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Display group 025 on the VCDS. Believe the long term fuel trim in a generic obd2 reader is the same as the partial load value.?


 

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Thanks, I just happened to have captured Group 025 last time I was using VCDS. ?

My values are:

Group 025 Oxygen Sensory Before CAT (B1-S1)
0.8% Oxygen Sensory Regulation
3.1% OS2 Adaptation Partial Load
-1.6% O2S Adaptation Idle
00110101 OS2 Control Status

Does that seem like it's OK or is 3.1% still suggesting some sort of vaccum or air leak?


On Apr 19, 2023, at 6:03 AM, rmartin1962@... wrote:

Display group 025 on the VCDS. Believe the long term fuel trim in a generic obd2 reader is the same as the partial load value.?
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I believe you are fine and I personally wouldn't be concerned or taking further action. General rule of thumb on considering it an issue on most vehicles is + or -7% for partial load/long term fuel trim whereas VW puts the spec at + or - 5%. A 3% deviation from the standard fueling map is not bad. Additional info here:??

Cheers, Bob


 

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@rmartin1962, @jheggest : any long-term reports from your PCV swaps?

For the 1997-2000 (AES) motor, the PCV valve fails, and the part is NLA (no longer available).
VW Part # 021-129-101D ( 021129101D ) which is the entire breather hose assembly (including the PCV valve).
This may also be known as VW 7M0128101 and Ford 7364573.
The part itself has 39-111-71-903 embossed on it.

Summary of Symptoms:
- no obvious drivability issues
- no CEL
- gas mileage may be lower
- VCSD Measuring block 025 may show OS2 Adaptation Partial Load (aka long term fuel trim) outside the range of -5% to +5%
Bob's van was +12.5%, mine is now also at +12.5%

I removed my PCV from my 2000 EVC. ?

It looks fine physically, is not clogged, and has no holes. ?But it is clearly not functional - you can blow or suck air through any of the 3 hoses and there is no restriction whatsoever.

I found some pictures of the internal construction of the same (similar?) model. ?People speculate that the problem is the diaphragm has stiffened and shrunk.
It might be possible to cut the part open and rig a new diaphragm.?

Ideas for using other parts as a replacement:

PCV Valve from a 1996 Audio A4 V6:?
PCV Valve from a 2.8L V6 Camaro:?/g/eurovanupdate/message/162539
PCV Valve from a 2001 Toyota:?/g/eurovanupdate/message/163832




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