1) Confirm symptom and purpose
- Action: Note oil in intake/intercooler, bluish/grey smoke, high oil consumption, oil leaks from rocker cover or dipstick, or whistling from breather.
- Theory: Blow‑by = combustion gases leaking past rings into crankcase. The blow‑by tube/PCV path vents that gas back into the intake so it’s burned. If the tube/separator is blocked, split, or the separator is saturated with oil, crankcase pressure rises and oil is pushed into places it shouldn’t.
- Why this matters: Diagnosing confirms you’re fixing the ventilation path rather than unrelated intake or turbo faults.

2) Locate and identify components on the 4D56
- Action: Find the crankcase breather on the valve/rocker cover and trace its hose to the oil separator (if present), then to the intake/turbo inlet or airbox.
- Theory: The layout lets pressure flow from crankcase → oil separator/trap → intake. Hoses, one‑way valves or separators remove oil droplets and return gases to the intake. Failure anywhere in that path causes symptoms.

3) Visual inspection and basic tests (before dismantling)
- Action: With engine off, remove cap/clamp and inspect hose condition, soft spots, cracks, hardening, blockages, or oil pooling. Remove the hose and blow through it or suck to check flow. Remove valve cover breather cap and check separator element/mesh for sludge.
- Theory: Rubber hoses age and collapse or crack; separators fill with oil/soot and block flow. A blocked path causes pressure buildup; a cracked path leaks unmetered air or oil.

4) Remove and clean components
- Action: Detach breather hose from rocker cover and intake/turbo. Remove oil separator/oil trap and clean with solvent/kerosene until oil and sludge are removed; dry thoroughly. Clean inside hose ends and mating surfaces. Clean intercooler/turbo and intake if heavy oil contamination is present.
- Theory: Cleaning restores free flow and oil separation. Removing oil deposits recovers airflow and prevents further ingestion of oil into the intake/turbo where it burns or reduces turbo efficiency.

5) Replace damaged parts
- Action: Replace any brittle, collapsed, split or internally clogged hoses, O‑rings, clamps and the oil separator element if it’s not serviceable. Use OEM or quality fuel/oil‑resistant hose rated for heat and vacuum. Refit with secure clamps and correct routing.
- Theory: New hoses maintain cross‑section and sealing. A good separator traps oil droplets and returns them to the sump instead of letting them pass into the intake. Proper routing prevents kinking and heat‑related deterioration.

6) Reassemble and restore connections
- Action: Reattach hoses in correct order and orientation. Ensure one‑way valves (if fitted) are installed correctly. Tighten clamps snugly (don’t over‑torque). Reconnect any sensors removed.
- Theory: Properly reconnected and sealed path ensures crankcase gases are vented through the separator to the intake at the designed flow rate and pressure.

7) Test and verify
- Action: Start engine, let it warm, and observe for oil leaks, reduced smoke, normal idle and suction through the breather. Compare crankcase pressure (cap off) to normal (should be slight vacuum or near atmospheric, not positive high pressure). Reinspect intercooler/intake after a drive for reduced contamination.
- Theory: Restored vent path reduces crankcase pressure, preventing oil from being forced into intake and reducing visible symptoms.

8) If symptoms persist — check for excessive blow‑by
- Action: Perform compression or leak‑down tests on each cylinder. If blow‑by is excessive, consider piston ring/cylinder wear diagnosis and plan for engine overhaul, piston ring replacement, or top end rebuild.
- Theory: The breather system only manages normal blow‑by. If rings are worn or cylinders scored, combustion gases will overwhelm the breather design; cleaning/replacing hoses won’t stop the root cause.

How the repair fixes the fault (concise)
- Replacing/cleaning the breather tube and oil separator restores the intended path for crankcase gases and the oil‑separation function. That prevents pressurization of the crankcase which otherwise forces oil out of seals and into the intake/turbo. Cleaning the intake/intercooler/turbo removes oil deposits that cause smoke and performance loss. If excessive blow‑by remains after the breather path is healthy, the fundamental cause is internal engine wear (rings/cylinders) which requires mechanical overhaul.

Done.
rteeqp73

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Galloper / Montero / Pajero 4D56 STRAIGHT PIPE exhaust SOUND ever wondered what a straight pipe (no muffler) 4D56 sounds like? well here it is.

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