Positive Crankcase Ventilation: Service and Repair
Positive Crankcase Ventilation (PCV) Valve ReplacementRemoval Procedure
1. Remove the upper intake manifold sight shield using the following procedure:
1.1. Remove the retaining bolt in the front of the shield.
1.2. Lift-up on the front of the shield.
1.3. Lift the shield off the rear bracket.
Important: After removing the turbocharger air ducts and hoses, cover the turbocharger openings and the ducts with tape to prevent entry of objects.
2. If removing the right side, remove the charged air cooler outlet duct from the air cleaner and the turbocharger.
3. If removing the right side, loosen both charged air cooler outlet duct to intake hose clamps.
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
4. Remove the charged air cooler outlet duct to intake hose.
5. If removing the left side, loosen the charged air cooler inlet duct to turbocharger clamp.
Important: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
6. Remove the charged air cooler inlet duct to turbocharger cool air outlet hose from the turbocharger. The hose can stay on the pipe.
7. In order to access the right side remove the heater outlet hose bracket and nut (1).
8. Remove the heater outlet hose bracket bolt (2).
9. Move the heater hose out of the way.
10. Remove the screws retaining the PCV diaphragm cover to the valve rocker arm cover.
11. Remove the diaphragm cover.
12. Remove the diaphragm and the spring.
13. Clean the diaphragm cover, spring, and screws.
14. Inspect the diaphragm for cuts or damage.
15. Discard the diaphragm if damage is found.
Installation Procedure
1. Install the spring, diaphragm and cover to the valve rocker arm cover.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the PCV diaphragm cover screws.
^ Tighten the PCV diaphragm cover screws to 4 Nm (35 inch lbs.).
3. Re-position the heater hose.
4. Install the heater outlet hose bracket nut (1).
^ Tighten the nut to 9 Nm (80 inch lbs.).
5. Install the bolt (2) retaining the heater outlet hose to the generator bracket.
^ Tighten the heater hose bracket bolt to 25 Nm (18 ft. lbs.).
6. Install the charged air cooler inlet duct to turbocharger cool air outlet hose to the turbocharger.
7. Position the clamp as shown for proper clearance.
^ Tighten the clamp to 6 Nm (53 inch lbs.).
8. Install the charged air cooler outlet duct to intake hose. The hose is marked DUCT which connects to the charged air cooler outlet duct.
The hose is marked ENG which connects to the intake manifold duct. Align the marks on the hose with the alignment marks on the pipe and duct.
9. Position the clamps as shown for proper clearance.
^ Tighten the clamps to 6 Nm (53 inch lbs.).
10. Install the air cleaner outlet duct to the air cleaner.
11. Install the air cleaner outlet duct to turbocharger. Align the duct to the air cleaner.
^ Tighten the air cleaner outlet duct clamps to 6 Nm (53 inch lbs.).
12. Install the upper intake manifold sight shield.
^ Tighten the upper intake manifold shield bolt to 9 Nm (80 inch lbs.).