Positive Crankcase Ventilation: Service and Repair
Crankcase ventilation, cleaning
Note! Some variation in the illustrations may occur, but the essential information is always correct.
Removing
Remove:
- the battery negative cable. Refer to: Battery, disconnecting Battery Disconnecting
- the auxiliaries belt. Use999 7109 Wrench 999 7109 Wrench
- the inlet hose for inlet hose to the control module, if applicable.
Remove:
- the screw for the charge air pipe over the engine
- the clamp for the power steering pump delivery line from the intake manifold
- the charge air hose from the charge air cooler (CAC).
Push the charge air pipe with the hose to one side.
If the car has lock brackets
Remove:
- the lock bracket (2) by removing the screw (1)
- the pipe nipple at the pump.
Place paper towels under the power steering pump to absorb any power steering pump fluid.
Install a hose clamp on the power steering pump hose
Remove the pressure line from the power steering pump. Plug the power steering pump and pipe using rubber plugs.
Disconnect the connector from the belt cover above the power steering pump.
Remove the power steering pump's 3 x mounting screws through the pulley holes.
Remove:
- the servo hoses and the engine coolant hoses from their holders/clips. Remove the tie strap for the servo hose by the suspension turret
- the servo reservoir from its mounting on the expansion tank for coolant
- the connector and place the servo reservoir on the engine.
Place the power steering pump on the engine.
Removal of alternator
Remove:
- the upper screw for the generator
- the screws common to the generator and the compressor.
Slacken off the lower screws for the compressor (so that there is some clearance).
Rest the generator against the radiator and the A/C compressor.
Cleaning
Note! For tightening torques, see: Tightening torque Tightening Torque
Remove the pipe screws from intake manifold.
Disconnect the hose (1) from the nipple.
Remove the oil filler cap.
Blow the hose (1) clean with compressed air.
Clean the hose with an electrical cable - 2.0 mm
Note! If the hose is clogged, use a welding rod (max - 2.0 mm , approximately 250 mm long) to clean the hose.
Clean the nipple (2) using a - 2.0 mm drill or a welding rod.
Install:
- the hose on the nipple
- the pipe screws with new gaskets
- the oil filler cap.
Raise the vehicle.
Remove the splashguard under the engine.
Tighten the pipe screws.
Install the splashguard under the engine.
Lower the vehicle.
Installing
Installing alternator
Install:
- the generator in the correct position
- the upper screw, but do not tighten
- both screws common to the generator and A/C compressor, but do not tighten.
Tighten:
- the upper screw
- the lower screws for the A/C compressor
- the screws common to the generator and the A/C compressor.
Installing the power steering pump
Install:
- the power steering pump in the correct position
- the 3 x screws through the pulley.
Install the delivery pipe on the power steering pump. Use a new O-ring on the pressure line.
Remove the hose clip.
If the car has lock brackets
Install the lock bracket (2).
Tighten the screw (1).
Note! There may be a gap (3) of a few millimetres between the pipe coupling and the power steering pump. Bend the bracket so that the twelve edged mounting on the bracket is on the nut.
Install:
- the auxiliaries belt. Use999 7109 Wrench 999 7109 Wrench
- the connector with holder on the power steering pump
- the servo reservoir in its mounting on the expansion tank
- the hoses in their holders and clips
- the tie strap for the servo hose at the suspension turret.
Install:
- the charge air hose on the charge air cooler (CAC)
- the screw for the charge air pipe above the engine and clamp for power steering pump delivery lines from the intake manifold
- cold air inlet hose to the control module.
Check the level in the servo reservoir and top up if necessary.
Connect the negative battery lead. Refer to: Battery, disconnecting Battery Disconnecting
Start the engine and check for leakage.