Crankcase Ventilation Kit Installation Instructions - Riffraff Diesel
Crankcase Ventilation Kit Installation Instructions Page 1 of 4
IMPORTANT: Before starting installation, please be sure that all items which were supplied with the kit are accounted for. 1 – 4” powder coated tube 2 – ¾” tubing clamps 2 – Viton o-rings 4 pages of installation instructions
1 – 5’ fuel/oil rated hose 1 – ¾” tubing connector 3 – zip ties
Installation: 1. Remove Air Intake Hose and Air Box lid – leave hose attached to lid. If you no longer use the stock air box, you may need to also remove the filter element or cold air intake box. Again, it is simpler to leave the air intake tube on either the element or cold air intake box.
2. Disconnect the crankcase ventilation hose at the plastic intake tube (the piece between the doghouse and the hard turbo inlet tube). Do not discard the crankcase ventilation hose or remove it from the doghouse - you will need it for Step #4. The green arrow indicates where to find the ventilation hose under the coupler. TIP: pack a clean rag into the hard turbo inlet tube after removing the coupler to keep out debris, etc.
3. Remove the two Phillips head screws that hold the doghouse in place on the driver side valve cover. Lift the doghouse off the valve cover and remove the two
O-rings are here.
Toll Free Sales & Customer Service: (866) 446-3360
Crankcase Ventilation Kit Installation Instructions Page 2 of 4 o-rings from the extensions that go into the valve cover. Install the new Viton o-rings which were supplied with the kit Rotate doghouse 180° and re-install onto the valve cover. CAUTION – do not over tighten the screws or you will crush the doghouse.
4. Rotate the 90° hose elbow from the 12:00 position (vertically straight up) to almost the 3:00 position – be careful to maintaining a slightly upward tilt. Insert the supplied ¾” hose connector and slide both new ¾” hose clamps over the hose connector and onto the elbow. Install the new ¾” hose over the bare end of the hose connector, slide the hose clamps into position (one on the elbow and the other on the new hose), and tighten the hose clamps securely.
5. Route the new hose over the brake master cylinder mounting base where it connects to the firewall as indicated in the picture. Route the hose downward to the frame rail, being very careful to avoid having the hose rub against wiring or touching any exhaust system components.
Toll Free Sales & Customer Service: (866) 446-3360
Crankcase Ventilation Kit Installation Instructions Page 3 of 4 IMPORTANT: Make sure the hose does not have any low points (sags or dips) where condensation or oily residue will collect and prevent free ventilation flow. This condition can cause the crankcase to become over-pressurized and result in oil leaks around your engine. Secure the hose with supplied zip ties, and allow the hose to discharge freely into the open air.
6. Remove the rag from the turbo intake tube, and install the new 4” powder coated tube into the turbo intake tube. Re-install the air intake hose and stock air box lid (or filter element/cold air intake box, etc.). CAUTION: Before tightening the clamps around your intake tube, etc., make sure it does not rub against either A – aluminum turbo outlet tube, OR B – brake master cylinder.
Once you are finished, re-check the doghouse screws and all clamps for tightness. O final recommendation. You should seriously consider removing and cleaning your charge air cooler (also referred to as the air-to-air cooler, or intercooler). The extent of oily residue contamination can be very extensive throughout your air intake system. These pictures reveal how the oily residue had made it all the way through this 2003 engine’s system (7.3L with 132,000 miles). Residue had accumulated in the lip of the hot side intercooler pipe where it connects to the spider, right before entering the air intake plenums and combustion chamber. You can even see the oil running down the spider’s adjoining connection nozzle. To clean the intercooler, you remove it, drain it out into a bucket, mix a strong solution of Simple Green and pour it in, slosh around and let it soak, rinse thoroughly, and reinstall. Toll Free Sales & Customer Service: (866) 446-3360
Crankcase Ventilation Kit Installation Instructions Page 4 of 4 Credit for pictures and information to PonyBoyChris, F250_, and the whole FTE crew. Thanks! If you are interested in a CCV catch can (trap) to prevent condensed vapors from dripping onto the ground, driveway, garage floor, etc., contact PonyBoyChris on FTE.
Disclaimer of Warranties and Liabilities Riffraff Diesel disclaims any implied warranties of merchantability and fitness for a particular purpose. Riffraff Diesel also disclaims any liability or consequential damages including, but not limited to, repair labor, rental vehicles, hotel cost, or any other inconvenience costs. This warranty is in lieu of all other warranties or guarantees, either expressed or implied, and shall not extend to any consumer or to any person other than the original purchaser.
Toll Free Sales & Customer Service: (866) 446-3360
IMPORTANT: Before starting installation, please be sure that all items which were supplied with the kit are accounted for. 1 – 4” powder coated tube 2 – ¾” tubing clamps 2 – Viton o-rings 4 pages of installation instructions
1 – 5’ fuel/oil rated hose 1 – ¾” tubing connector 3 – zip ties
Installation: 1. Remove Air Intake Hose and Air Box lid – leave hose attached to lid. If you no longer use the stock air box, you may need to also remove the filter element or cold air intake box. Again, it is simpler to leave the air intake tube on either the element or cold air intake box.
2. Disconnect the crankcase ventilation hose at the plastic intake tube (the piece between the doghouse and the hard turbo inlet tube). Do not discard the crankcase ventilation hose or remove it from the doghouse - you will need it for Step #4. The green arrow indicates where to find the ventilation hose under the coupler. TIP: pack a clean rag into the hard turbo inlet tube after removing the coupler to keep out debris, etc.
3. Remove the two Phillips head screws that hold the doghouse in place on the driver side valve cover. Lift the doghouse off the valve cover and remove the two
O-rings are here.
Toll Free Sales & Customer Service: (866) 446-3360
Crankcase Ventilation Kit Installation Instructions Page 2 of 4 o-rings from the extensions that go into the valve cover. Install the new Viton o-rings which were supplied with the kit Rotate doghouse 180° and re-install onto the valve cover. CAUTION – do not over tighten the screws or you will crush the doghouse.
4. Rotate the 90° hose elbow from the 12:00 position (vertically straight up) to almost the 3:00 position – be careful to maintaining a slightly upward tilt. Insert the supplied ¾” hose connector and slide both new ¾” hose clamps over the hose connector and onto the elbow. Install the new ¾” hose over the bare end of the hose connector, slide the hose clamps into position (one on the elbow and the other on the new hose), and tighten the hose clamps securely.
5. Route the new hose over the brake master cylinder mounting base where it connects to the firewall as indicated in the picture. Route the hose downward to the frame rail, being very careful to avoid having the hose rub against wiring or touching any exhaust system components.
Toll Free Sales & Customer Service: (866) 446-3360
Crankcase Ventilation Kit Installation Instructions Page 3 of 4 IMPORTANT: Make sure the hose does not have any low points (sags or dips) where condensation or oily residue will collect and prevent free ventilation flow. This condition can cause the crankcase to become over-pressurized and result in oil leaks around your engine. Secure the hose with supplied zip ties, and allow the hose to discharge freely into the open air.
6. Remove the rag from the turbo intake tube, and install the new 4” powder coated tube into the turbo intake tube. Re-install the air intake hose and stock air box lid (or filter element/cold air intake box, etc.). CAUTION: Before tightening the clamps around your intake tube, etc., make sure it does not rub against either A – aluminum turbo outlet tube, OR B – brake master cylinder.
Once you are finished, re-check the doghouse screws and all clamps for tightness. O final recommendation. You should seriously consider removing and cleaning your charge air cooler (also referred to as the air-to-air cooler, or intercooler). The extent of oily residue contamination can be very extensive throughout your air intake system. These pictures reveal how the oily residue had made it all the way through this 2003 engine’s system (7.3L with 132,000 miles). Residue had accumulated in the lip of the hot side intercooler pipe where it connects to the spider, right before entering the air intake plenums and combustion chamber. You can even see the oil running down the spider’s adjoining connection nozzle. To clean the intercooler, you remove it, drain it out into a bucket, mix a strong solution of Simple Green and pour it in, slosh around and let it soak, rinse thoroughly, and reinstall. Toll Free Sales & Customer Service: (866) 446-3360
Crankcase Ventilation Kit Installation Instructions Page 4 of 4 Credit for pictures and information to PonyBoyChris, F250_, and the whole FTE crew. Thanks! If you are interested in a CCV catch can (trap) to prevent condensed vapors from dripping onto the ground, driveway, garage floor, etc., contact PonyBoyChris on FTE.
Disclaimer of Warranties and Liabilities Riffraff Diesel disclaims any implied warranties of merchantability and fitness for a particular purpose. Riffraff Diesel also disclaims any liability or consequential damages including, but not limited to, repair labor, rental vehicles, hotel cost, or any other inconvenience costs. This warranty is in lieu of all other warranties or guarantees, either expressed or implied, and shall not extend to any consumer or to any person other than the original purchaser.
Toll Free Sales & Customer Service: (866) 446-3360
