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New PCV Wont Install Flush into Valve Cover


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gman28
User

Aug 14, 2015, 8:10 AM

Post #1 of 8 (889 views)
New PCV Wont Install Flush into Valve Cover Sign In

2002 Ford Focus, 2.0L SPI Engine, 82,865 miles.

My PCV hose was collapsed and needed to be replaced. I picked up the new part from a Ford Dealer - Part YS4Z6758A. The lower rubber 90º elbow was ripped, and you can't buy just the elbow, thus I was forced to buy the new part.

I then decided to buy a new MotorCraft PCV valve and completely replace the entire system. I removed the old PCV valve by turning it counter-clockwise. My problem is the new PCV valve won't go in all the way. I can't get it past the o-ring gasket. I can put the old unit back in turning it clockwise and it sits flush into the valve cover.

Has anybody experienced this problem and came up with a fix? Looking at the problem, the previous owner or shop might have tried to force it out using a pry bar or screwdriver, thus distorting the two pins at 9 & 3.

Look forward to a solution.

gman28


Discretesignals
Ultimate Carjunky / Moderator
Discretesignals profile image

Aug 14, 2015, 9:49 AM

Post #2 of 8 (872 views)
Re: New PCV Wont Install Flush into Valve Cover Sign In

Did you lubricate the o ring?





Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Aug 14, 2015, 9:57 AM

Post #3 of 8 (869 views)
Re: New PCV Wont Install Flush into Valve Cover Sign In

Are you just fighting with a rubber grommet I'll call it in the valve cover? Will the old PCV still go in? Right parts?


Much of this stuff is better found IMO at parts outlets namely NAPA for the grommet + for certain odd things places like Autozone have a section with parts made by "HELP" for common stuff but it's important.


BTW - This area and the elbows if like I think would split easily - not good for your engine as that's a vacuum leak.


Trick for that either permanent or temporary for elbows is to get PCV hose of the ID you need if room allows you can make an elbow with a longer stretch of hose with a pretzel like twist/loop if that fits, doesn't rub anything and out of the way can be the better permanent fix.


If this area was already messed with and non OE sizes of that valve cover part forced in somehow the problem would be with that now,


T



gman28
User

Aug 14, 2015, 10:13 AM

Post #4 of 8 (867 views)
Re: New PCV Wont Install Flush into Valve Cover Sign In

Yes, I did, but it won't even slide past the ring. In short, it stops before getting to the gasket. The valve body has slots that are supposed to slide up and then turn. Once it turns fully, it draws the gasket in and sits flush with the valve cover.

It's acting like the two posts are bent or misaligned, thus preventing the valve from rotating. But like I mentioned in my first post, the old unit turns in and out perfectly.

One question you might be able to answer: Can the valve cover be removed without taking off the timing belt cover? If so, there are only three bolts. Once off, I could see what the hangup is. I don't want to remove the timing belt cover because I just paid Ford to change the belt, pulley, and water pump two days ago. They told me that they would change the pcv valve for $200.00 for the parts & labor.

gman28


gman28
User

Aug 14, 2015, 10:35 AM

Post #5 of 8 (863 views)
Re: New PCV Wont Install Flush into Valve Cover Sign In

Q: Are you just fighting with a rubber grommet I'll call it in the valve cover?

Ans: Yes

Q: Will the old PCV still go in?

Ans: Yes it will still go in & out. When you shake the old pcv valve, you hear a little movement. When you shake the new one, you hear a lot more movement.

Q: Right parts?

Ans: Yes, it's a MotorCraft part purchased from my local Ford dealership.

Thanks for the tip on how to solve the 90º elbow problem using tubing and making a pretzel-like fix. I will try that fix the next time the elbow fails.

One question you might be able to answer: Can the valve cover be removed without taking off the timing belt cover? If so, there are only three bolts. Once off, I could see what the hangup is with the pcv valve. I don't want to remove the timing belt cover because I just paid Ford to change the belt, pulley, and water pump two days ago. They told me that they would change the pcv valve for $200.00 for the parts & labor. So, I decided to do it myself.

gman28


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Aug 14, 2015, 11:23 AM

Post #6 of 8 (858 views)
Re: New PCV Wont Install Flush into Valve Cover Sign In

OK - You've mostly answer the question I had. Wrong parts from Ford or not doesn't matter. Now put old one in if it still fits and get a matched set of PCV and think your are saying damaged grommet that will fit into your valve cover. Think you are totally screwed to cut that grommet out now to match up or be without a car for a while.


It's always a challenge on my end not seeing the issue right in front of me no matter how good any pics you can come up with some things you just need to see. High chance this got cobbled to work possibly at some quick oil change place where funky mysteries happen too much now YOU have the problem.


Get proper new grommet so you can see if it has any tricks. You should be able to cut old one while held with either needle nose locking pliers or even tricks like poke right thru it with something like a mechanic's dental pick so it can't fall out/down forcing you to take valve cover off.


Ford Focus: Plenty I'll never know year by model year and part year changes. I think the original was a Toyota and no clue how much Ford was involved with what. The companies do that stuff and only the best software without mistakes (rare) will know which one of what to ask for.


Not sure but can get down to providing the VIN and if still there matching driver's door jam should say month and year the car was made.


It's probably too old to go jumkyarding for parts like this unless by chance there are lots and one just done.


For now I see this as a parts mix up and or mess to undo and get right so it's never troublesome again,


T



gman28
User

Aug 14, 2015, 1:13 PM

Post #7 of 8 (850 views)
Re: New PCV Wont Install Flush into Valve Cover Sign In

Tom,

I solved the problem in an unorthodox way. I noticed that the new part was grooved and was a tad longer. So, I took my Dremel tool and took 1/32 of each end. Then I rotated the valve until I felt the expanded channel made contact with the post in the valve cover. I then tapped the unit to help it into the opening. Then I turned it slowly with a wrench, keeping pressure on the valve. It finally fell into place, and I'm hoping that I don't have to mess with it for another 8 years.

I wish to thank all who chimed in to assist me.

gman28


Tom Greenleaf
Ultimate Carjunky / Moderator
Tom Greenleaf profile image

Aug 14, 2015, 1:27 PM

Post #8 of 8 (847 views)
Re: New PCV Wont Install Flush into Valve Cover Sign In

If it's working properly let it be.


Just FYI - PCV is a system with that valve to draw the fumes in to burn off rather than let them out to air or if engine left unvented/under a trace of vacuum in crankcase areas which a valve cover is it would harm the oil or if allowed to build up pressure find the easiest other place to vent or leak.
You can tell if it tight and working properly and an indication of good engine health is to just pull up oil dipstick enough or all the way so it isn't sealed. Smoke at engine idling should be drawn down dipstick tube - that easy. Smoke or even flame (AYOR) from a common lighter will pull flame down. If one blows OUT I can't see how it's working as the design is intended,


T







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