Crank Case Vent (CCV) Bypass Modification

January 4, 2005
Written by: CHPMustang
Edited by: E. Long
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Introduction

This installation outlines the Crank Case Vent Bypass Modification, otherwise known as the CCV mod. This modification was done with over-the-counter parts from the local NAPA Auto Parts store. Similar parts stores in your area will also sell these parts. You may also find complete kits available on Ebay for an inflated cost...but convenient, nontheless. Search for "CCV mod" on ebay.

CCV Background

The CCV exists to evacuate crankcase pressure from the engine. It introduces the gases (oil vapors) into the air intake system for clean burnoff by the combustion process. I also suspect it has to do with EPA restrictions for cleaner exhaust fumes and the strict California air quality guidelines. Diesels however aren't smogged (emissions tested in CA). If you suspect this modification will violate EPA restrictions in your state, then it would be in your best interests to not perform this modification!

Benefits

The immediate benefit of this modification is the elimination of surface coating oil vapors which coat the intercooler. Oil vapors that coat the intercooler can reduce the intercooler's efficiency -- thus reducing performance and MPG.

Goal

The goal of this modification will be to eliminate the oil vapors from mixing with the clean, fresh air going to the engine. This will put a stop to the oil vapors that coat the intake tube, intercooler, boost tubes, boots, and clamps with oil.

Parts needed for this project

7-feet of 3/4-inch ID standard coolant hose (can use clear) or Parker Hose which is diesel-fuel rated
(1) coupler for 3/4" ID hose
(2) screw clamps for the hose
(6) plastic wire zip ties
(1) Cap or plug for the bottom of the fume collector

Time Requirements

Less than 1 hour

Difficulty

2 out of 10 (1 being easiest, 10 being hardest)

Step 1: Remove air intake tubes

1.) Remove the air intake tube from the filter box to the black fume collector (bolted to an engine-mounted bracket). 2.) Remove the intake tube going from the collector to the turbocharger impeller opening.

Step 2: Unbolt the CCV collector

1.) Unbolt the 2 CCV collector bolts. 2.) Slip off the black elbow attached to the bottom of the collector.

Step 3: Elbow dress-up

1.) Cap off the bottom of the elbow where it previously attached to the collector. By doing this, you prevent dirt from entering the fresh air flow to the engine. 2.) Trim off the CCV shroud within the collector to promote better airflow. Be sure not to leave any shavings in the collector (to avoid shavings being sucked into the turbo)! Or alternatively, you can substitute 3.5"x4" exhaust pipe or PVC pipe like other PowerStroke owners have done (see the bottom two pics to the left).

Step 4: Route new hose

1.) Take the hose end and route it from the CCV elbow down towards the ground. Be sure to keep it as far away from the exhaust manifold as possible to melting the tube. 2.) Run the hose to the trany support member. Make sure the hose is the LOWEST part of the run as you want to avoid oil residue from pooling inside the tube. 3.) With the hose in place, take the plastic coupler and insert it into the CCV elbow located on the CCV cover and clamp it. 4.) Take the end of the hose and clamp it, too. 5.) Double-check the clamps to ensure they are tight. Zip tie the hose to non moving parts along the fender and frame area.

Step 5: Final Step

1.) Reinstall the CCV collector (with the CCV fume connection unplugged) along the air intake tubes. 2.) Start the engine. One thing you'll notice when the engine is running is an appearance of steam and/or light smoke. Don't be alarmed, it is purely crankcase oil vapors which are normal. The vapors will be more visible when the outside temperatures are colder.

Conclusion

My conclusion is the engine area benefitted from the elimination of oily residue on the boost tube, boots, clamps, and all interior airflow surfaces. The biggest compliment I get now is "How do you keep the boots so clean?" The engine area is much cleaner after this modification. The Excursion seemed to accelerate somewhat better but nothing really "seat of your pants" like adding a programmer for example, but noticeable nevertheless. I did not get a chance to document change in MPG, but I'd have to say it would be on the gain side of MPG. Something that owners could also benefit from is the prevention of the boost tube boots blowing off under hard acceleration or high boost psi numbers as the boots were coated/soaked with oil and were prone to blowing off -- causing a loud turbo scream under the hood with black smoke coming off the tailpipe.

Additional Questions or Comments?

Do you have additional questions or comments about this install article? Please discuss them in this forum thread.

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