CCV Cleanout with Pictures

[Seabass]

Following the recent freeze up of my crank case vent (CCV) valve (and $1800 repair bill), I'm posting a few pictures. I didn’t really post this as a DIY since I’m not a mechanic and I’d like some advice from those who are more knowledgable. I'm hoping to spur on some discussion. If there is demand for a DIY, I can take some step-by-step pics next time.

The CCV is a simple diaphragm valve that vents any crank case pressure back to the intake manifold.

I drive a 2005 4.4i (N62 engine) and live in Edmonton, Canada (routine winter temps down to -15°C and as low as -30°C). As stated, the CCV recently froze and when I started the car, I overpressure the right side cylinder head cover, oil everywhere. I had my vehicle towed to the local dealer and they replaced the right side head cover and gaskets. All said and done: $1800 CDN. They installed an upgraded head cover and vent hose/valve. You'll see the difference between the new right style and old left style in my pictures.

The dealer noted that I had an extremely high amount of moisture in the engine (usually caused by short trips and excessive idling). I'm the second owner and must blame the previous owner for the moisture build-up (but alas I have to deal with it). The dealer did a hot oil change in an effort to remove some moisture. I've recently done a second hot oil change (500km after the dealer did it).

The dealer advised that I drive in manual mode and run the engine hard in an effort to build temperature and vaporize the built-up moisture.

Following my research and discussions with others, I've decided to play it safe and routinely check/clean my CCV valves in order to remove the sludge/moisture that builds up. Following the two oil changes and the harder driving, I'm still noticing sludge/moisture build up.

Anyway, here's the pics of my procedure. Note that in these pictures, you will not see a lot of white sludge (indicative of moisture), as I didn't think to pull out my camera until I cleaned most of it out. (I'll follow up with a picture of the sludge, next time I clean the valve).

If you intend to do this yourself; the standard disclaimer applies. Be confident in your skills before attempting this. I won’t be held responsible if you mess things up!

The following picture shows the 4.4i Valvetronic engine (cover removed). The right side CCV is visible. I have an upgraded right head cover which does not have an internal CCV. It is located at the midway point of the vent hose.



The following picture shows the LEFT side cylinder head cover and integral CCV. This is the stock arrangement. Most people will have this type of valve arrangement on both sides (unless you’ve had a reason to replace head covers recently)



Through my experience, I haven’t seen any sludge/moisture on the left side, so I’m showing the pictures related to the Right side only. First I remove the hose. No tools needed, just squeeze the end connectors and pull straight off. I carefully remove the CCV cap by prying off the plastic retaining tabs with a flat screwdriver (these are easily broken if pried too far). I normally do this with a warm engine as the retaining tabs are very brittle when cold. If you are working on the old style configuration (see my Left side pic), you have to remove the cap from the head cover. You have to get under the hood and carefully pry off the retaining tabs to get the cap off. AGAIN: be careful not the break the tabs!

Once your remove the cap, carefully extract the orange rubber diaphragm (by hand). It is soft rubber and will be easily damaged with a screwdriver. The spring sits behind the diaphragm. As stated, I already cleaned this out before taking pictures so there is no sludge/water visible. (I usually pull out about a tablespoon of white sludge from the valve housing and hoses). It’s also normal for about a teaspoon of water to pour out when I remove the hose. I blow compressed air through the hoses to get as much sludge/water out as possible.



Here is some remaining sludge for those that aren’t familiar. It the same “cheese whiz” that some owners typically find under their oil cap. It’s just a mixture of water and oil.



Here is another pic showing the hose connection points (right valve cover and intake manifold). White sludge is visible inside both hose connections.



Now I reassemble (and repeat weekly!)

Thoughts, comments?

Matt