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TSB 25-001-06

Positive Crankcase Ventilation (PCV) System Freezes
In Extreme Cold Ambient Temperatures

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Date: Feb. 1, 2006   

Models: 2002 -2005 (DR) Ram Truck

NOTE: This bulletin applies to vehicles equipped with 4.7L engines, sale code “EVA”.

Overview:
This bulletin involves installing revised PCV system components.

Symptom/Condition:
Some customers operating in extreme cold ambient temperatures (Below 0°F or Neg.
18°C) may experience moisture collecting in the PCV system and freezing. This can lead
to a variety of cold engine crankcase venting or driveability symptoms.

Diagnosis:
If a customer indicates that they are experiencing any cold engine crankcase venting or
driveability symptoms, perform the Repair Procedure.

Parts Required:
Qty. Part No. Description
1 05191104AA PCV Kit

Repair Procedure: 

2002 DR - 4.7 L
1.      Remove the existing PCV tube and retain for fabrication of new PCV tube(Fig. 1).
2. Replace oil fill housing with 53020891AE (oil fill without PCV valve)(Fig. 1).
3. Remove the existing CCV tube and retain for fabrication of new PCV tube.(Fig. 1).
4. Cap the resonator port with the cap provided.
5. Remove the left breather fitting in the cylinder head and discard.
6. Remove the existing airbox cover and replace with p/n 53032405AC
7. Install the new CCV tube (53032819AA) as shown(Fig. 3).
8. Tighten the Adapter Assembly - PCV (53032925AC) into the left breather fitting
location in the cylinder head to 35Nm (26 Ft. Lbs.) .
9. Use thew original PCV tube to fabricate a PCV tube from the PCV Adapter Assembly
to the intake manifold PCV port ensuring that there are no low spots in the tube for
water to collect(Fig. 2).
10. Instal the PCV tube as shown(Fig. 3).
11. Install the Authorized Modification label, p/n 04275086AB.
12. Clean the area next to the VECI Label with an appropriate solvent and install the new
vacuum schematic, p/n 52022300AA, next to the VECI label.
  fig 1 fig 2 fig 3
 
2003 and Early 2004 DR - 4.7 L
1.      Remove the existing PCV tube and discard(Fig. 4).
2. Replace oil fill housing with 53020891AE (oil fill without PCV valve)(Fig. 4).
3. Remove the CCV tube and discard(Fig. 4).
4. Cap the resonator port with the cap provided(Fig. 4).
5. Remove the left breather fitting in the cylinder head and discard(Fig. 4).(Fig. 4).
6. Remove the existing airbox cover and replace with p/n 53032405AC(Fig. 4).
7. Install the new CCV tube (53032819AA) as shown(Fig. 5).
8. Tighten the Adapter Assembly - PCV into the left breather fitting location in the cylinder
head to 35Nm (26 Ft. Lbs.).
9. Route the new PCV tube to the intake manifold PCV port as shown(Fig. 5).
10. Install the Authorized Modification label, p/n 04275086AB.
11. Clean the area next to the VECI Label with an appropriate solvent and install the new
vacuum schematic, p/n 52022300AA, next to the VECI label.
  fig 4 fig 5
 
Late 2004 and 2005 DR - 4.7 L
1.      Remove existing PCV tube and discard(Fig. 6).
2. Replace oil fill housing with 53020891AE (oil fill without PCV valve)(Fig. 6).
3. Remove the CCV tube and dispose(Fig. 6).
4. Remove the left breather fitting in the cylinder head and discard.
5. Remove the existing airbox cover and check the part number on the underside. If it is
not p/n 53032405AC, replace with this part number(Fig. 6).
6. Install the new CCV tube (53032819AA) as shown(Fig. 7).
7. Tighten the Adapter Assembly - PCV into the left breather fitting location in the cylinder
head to 35Nm (26 Ft. Lbs.).
8. Route the new PCV tube to the intake manifold PCV port as shown.(Fig. 7). The PCV
tube should not touch the EGR system.
9. Install the Authorized Modification label, p/n 04275086AB.
10. Clean the area next to the VECI Label with an appropriate solvent and install the new
vacuum schematic, p/n 52022300AA, next to the VECI label.
  fig 6 fig 7

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:

Labor Operation No:   Description Amount
25-01-20-90 Install PCV Kit 0.7 Hrs.

Failure Code:

ZZ        Service Action

I would like to thank Bob Bergevin, Arthur Cantrall, Barry Drodge, David Lovell, Bill Maurits, and Steve for supplying the information for these bulletins. And a big thank you goes to Geno's Garage for making DodgeRam.info possible.

 

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This page was edited on: May 3, 2004