Old thread, but if anyone searches for "BOV Install"...
I found the Stanley ratchet wrench (purchased at Wally World) worked well: the edges are thinner and rounded, good for slipping passed that PITA oil line.
Tools Needed
8mm Socket & wrench, or flathead screwdriver
10mm Ratchet wrench (Buy a metric set if you do not have one, it will be worth every penny.)
My Procedure
1. Loosen both hose clamps on air intake downpipe with an 8mm socket (or flathead screwdriver, but I prefer using a socket wrench, especially on the lower one).
2. Remove airbox.
3. Disconnect downpipe from turbo and lay it across the hoopla behind the intake manifold. I saw no need to remove the power distribution cover or the surge valve vacuum hose as directed by the instructions.
4. With 10mm ratchet wrench, remove the three surge valve bolts, starting with the P.I.T.A. one (the one furthest away) by lowering the wrench with your left hand in front of the turbo and grabbing it with your right hand from behind the turbo. Aim with left hand, wrench with right hand. Using the ratchet wrench makes it unnecessary to go underneath the car.
5. Set surge valve on top of power distribution box.
6. Get the three bolts and lock-washers included in the kit. Obtain three flat-washers that will fit the bolt and the surge valve since the kit did not come with them. Assemble bolts and washers.
7. Place first bolt on top (closest) hole through surge-valve and BOV plate per instructions; fasten BOV assembly to turbo. Install second bolt. Alternately tighten both of them to torque, this will make installing the third bolt easier.
8. Install third bolt. Press against the steel line to get it in there and hand-screw it in as much as possible. Squeeze ratchet wrench onto the bolt to tighten it completely, just as in step #4. Button it all back together and enjoy!
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