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Perkins T6.3544 6.3544 and 6.3724 Diesel Engines Workshop Service Repair Manual

Summary first (one line): the PCV (crankcase ventilation) valve is a one‑way valve that lets blow‑by gases be drawn from the crankcase into the intake under vacuum and closes under boost/pressure — replacing a failed PCV restores that controlled flow, preventing crankcase overpressure, oil leaks, oil‑inlet contamination and smoking.

Tools & consumables
- New PCV valve (Perkins part or OEM equivalent), any O‑ring/grommet/hose recommended.
- Small screwdriver, pliers, hose‑clamp tool, pick.
- Clean rags, solvent (degreaser), lint‑free cloth.
- Hand vacuum pump or small gauge (optional for bench test).
- Torque wrench only if you remove rocker cover (not usually required).
- Safety gloves & eye protection.

Theory (brief, to understand the repair)
1. Blow‑by: combustion gases leak past piston rings into the crankcase. Those gases contain unburnt fuel, moisture and combustion products.
2. Purpose of PCV system: create a controlled path so these gases are evacuated from the crankcase into the intake to be burned, and maintain a slight vacuum in the crankcase to prevent oil leaks and foaming.
3. One‑way action: the PCV valve (or breather valve) allows flow from crankcase → intake under intake vacuum, but closes or restricts flow when intake is pressurized (preventing boost/backflow).
4. Failure modes:
- Stuck closed/blockage → crankcase pressure rises, seals/gaskets leak oil, oil foaming, exhaust smoke from burning oil, increased oil consumption.
- Stuck open → uncontrolled flow and possible boost pushing oil/air into intake, rough idle, black/blue smoke, fouled intake, turbo contamination (if turbocharged).
5. Replacement fixes the fault by restoring the one‑way, metered path for blow‑by: it re‑establishes crankcase vacuum control, prevents overpressure, and stops oil‑laden vapors entering intake uncontrolled.

Step‑by‑step replacement (in order)
1. Safety & prep
- Park engine on level, engine off and cool enough to work on.
- Wear gloves/eye protection and clean area around PCV to avoid contamination entering engine.
- If heavy dirt, brush off and wipe area around the valve before opening the system.

2. Locate the PCV valve
- On Perkins T6‑series engines the PCV/breather valve is mounted in the rocker cover or on a breather hose that connects the rocker cover to the intake plenum. Identify the valve body and the hose leading to intake.
- Note orientation/flow direction (crankcase side → intake side).

3. Inspect before removal (diagnostic)
- Look for oil leaks, oil soaked hoses, collapsed hoses or cracks.
- If possible bench/test the valve before throwing it away: remove and shake — many PCV valves contain a spring/ball and you should hear/feel movement. Use a hand vacuum pump or try blowing air through the valve in the intended flow direction (should pass) and against it (should block or restrict).
- Measure crankcase pressure if you want a quantitative check: connect vacuum gauge to the PCV port (or dipstick adapter). Normal slight vacuum at idle is expected; sustained positive pressure or no vacuum indicates problem.

4. Remove the old PCV valve
- Loosen hose clamps on both ends of the breather hose with screwdriver/pliers.
- Pull the hose off the valve. If the valve is seated in the rocker cover grommet, grasp and pull straight out — use a pick to ease the grommet if seized.
- If the valve is threaded or pressed into an adapter, remove retaining clips or unscrew as required.
- Inspect mating surfaces, hose condition and grommet. Replace any cracked hose or worn grommet.

5. Clean the mounting area
- Wipe the valve seat/grommet area clean of oil and debris. Use solvent on cloth — do not push dirt into the crankcase.
- Check that the intake side hose and clamps are clean and flexible.

6. Install the new PCV valve
- Confirm new valve orientation (arrow or larger end toward crankcase). One‑way orientation is critical.
- Insert valve into grommet/port or push into hose, ensuring full seating. Replace grommet if brittle.
- Refit hose onto the intake side and secure clamps snugly. Do not overtighten plastic hose fittings; clamp enough to seal.

7. Final checks before start
- Make sure no tools or rags remain in engine bay, clamps are secure, hoses are routed correctly.
- If you removed the rocker cover or any fasteners, refit and torque per Perkins spec (consult workshop manual for bolt torque if you did remove cover).

8. Start and test
- Start engine, let it warm to normal operating temperature.
- Observe for immediate issues: listen for hissing (vacuum leak) and check for oil leaks around the valve and hoses.
- Check idle quality and smoke. If rough idle or black/blue smoke persists, recheck hose sealing and valve orientation.
- Optional: re‑measure crankcase pressure/vacuum. You should see restored slight vacuum under normal idle conditions (or normal readings compared with spec).
- Road/test under load. Confirm no oil leaks and no increased oil consumption or turbo/oil contamination.

How this repair fixes the fault (concise)
- Replacing a blocked or failed PCV valve restores the one‑way metered evacuation of blow‑by gases. This removes excess pressure from the crankcase (stops seals leaking), prevents oil being forced into the intake under boost, stops oil vapor from condensing in the intake and turbo, and restores proper scavenging so the engine runs cleaner and uses oil properly. If the valve was stuck open, the new valve prevents uncontrolled backflow on boost and reduces oil ingestion and smoke.

Common pitfalls & notes (no fluff)
- Install with correct orientation. Backwards installation will not vent correctly and can cause boost to force oil into intake.
- Replace brittle hoses and grommets at the same time — a new valve on a leaky hose won’t solve the problem.
- Do not simply cap the vent — crankcase must be ventilated.
- If crankcase pressure problems persist after replacement, inspect piston rings, cylinder wear and turbo seals (severe blow‑by or turbo leaks can be underlying causes).
- Keep replacement parts clean; contamination introduced during replacement causes other failures.

That is the ordered procedure with theory and how the repair corrects symptoms.
rteeqp73

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