Oil Separator/PCV

Remove and replace the oil separator (PCV system) on the 2005 Dodge Viper 8.3L V10, including hose disconnection and reinstallation.

Warnings

Tools required

Parts

• Oil separator assembly × 1 — Mopar 05037618AA or equivalent
• Oil separator mounting gasket × 1 — Use OEM specification
• PCV hoses (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Allow engine to cool completely.
3. Open hood and secure in open position.
4. Disconnect negative battery terminal to prevent accidental electrical contact.
5. Place oil drain pan beneath work area to catch residual oil.

Procedure

1. 1

   Remove engine cover
   Remove the decorative engine cover by pulling upward on the cover to disengage the mounting grommets from the posts on the intake manifold. Set the cover aside in a clean area.
2. 2

   Identify oil separator location
   Locate the oil separator assembly on the engine as documented in the factory service manual for the 2005 Viper 8.3L V10. Identify the hose connections to the crankcase, intake, and oil return, verifying the actual number and routing against the FSM before disconnecting.
3. 3

   Disconnect PCV hose from intake manifold
   Disconnect the PCV outlet hose from the intake manifold connection point. This hose runs from the top of the oil separator to the intake. Use a flathead screwdriver to gently pry the hose clamp open or loosen the clamp, then twist and pull the hose free. Expect some oil residue.
4. 4

   Disconnect crankcase inlet hose
   Locate and disconnect the crankcase inlet hose from the oil separator. This hose connects to the side of the separator body. Loosen or release the hose clamp and pull the hose free from the separator fitting. Allow any trapped oil to drain into the pan below.
5. 5

   Disconnect oil drain hose
   Disconnect the oil drain hose from the bottom of the oil separator. This hose returns separated oil to the crankcase or oil pan. Loosen the clamp and carefully remove the hose, allowing residual oil to drain into the pan.
6. 6

   Remove oil separator mounting bolts
   Remove the mounting bolts securing the oil separator to the engine block using the appropriate metric socket (verify exact bolt count against the factory service manual for the 2005 Viper 8.3L V10). Support the separator with one hand while removing the final bolt to prevent it from falling.
7. 7

   Remove oil separator assembly
   Carefully pull the oil separator assembly away from the engine block. The separator may have a mounting gasket or O-ring seal that will come off with the unit or remain on the block. Inspect the mounting surface on the block for any remaining gasket material.
8. 8

   Clean mounting surface
   Thoroughly clean the oil separator mounting surface on the engine block using shop towels and a suitable solvent if needed. Remove all old gasket material and oil residue to ensure a proper seal for the new separator. Do not scratch or gouge the sealing surface.
9. 9

   Install new oil separator
   Position the new mounting gasket on the engine block or on the back of the new oil separator as designed. Align the new oil separator assembly with the mounting holes and carefully press it into position. Install the mounting bolts and tighten them evenly to secure the separator firmly against the block (verify exact bolt count and tightening pattern against the factory service manual for the 2005 Viper 8.3L V10). Tighten the bolts to the torque specification listed in the factory service manual for the 2005 Viper 8.3L V10 oil separator (typical small M6 fasteners are approximately 7 ft-lbs; do not overtighten and risk crushing the gasket or stripping threads).
10. 10

    Reconnect oil drain hose
    Reconnect the oil drain hose to the bottom fitting of the new oil separator. Ensure the hose is fully seated on the fitting, then position and tighten the hose clamp securely to prevent oil leaks.
11. 11

    Reconnect crankcase inlet hose
    Reconnect the crankcase inlet hose to the side fitting of the oil separator. Push the hose fully onto the fitting and secure with the hose clamp. Verify the connection is tight and the hose routing does not interfere with any moving components.
12. 12

    Reconnect PCV hose to intake manifold
    Reconnect the PCV outlet hose from the top of the oil separator to the intake manifold fitting. Ensure the hose is fully seated and secure the connection with the hose clamp. Check that the hose is not kinked or stretched.
13. 13

    Reinstall engine cover
    Reinstall the decorative engine cover by aligning the mounting grommets with the posts on the intake manifold and pressing down firmly until the cover snaps into place.
14. 14

    Reconnect battery and test
    Reconnect the negative battery terminal. Start the engine and allow it to idle for several minutes. Monitor the oil separator area and all hose connections for any signs of oil leaks. Check that the engine idles smoothly without rough running or unusual vacuum leaks.

Reassembly

1. Verify all three hose connections (inlet, outlet, and drain) are secure and properly clamped.
2. Ensure no tools or shop towels were left in the engine bay.
3. Dispose of oil-soaked towels and any spilled oil properly.

Verification

• Start engine and verify smooth idle with no vacuum leaks or rough running.
• Inspect all oil separator hose connections for leaks while engine is running.
• Check mounting bolts are secure and separator is not vibrating excessively.
• After a short test drive, recheck all connections for any signs of oil seepage.

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