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Old 07-26-2007, 11:05 PM   #34
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Join Date: Sep 2004
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Location: Fairmont, WV
What I Drive: Turbo 04 DSG Mach 1

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Thanks everyone!
I talked to my tuner and he said to go with .035" gap for my plugs, and that I'd get spark blow out with .055".

Day 10

Hard to believe I've been at this for 10 days now.

Start time: ~6:00pm
End time: ~11:15pm

Today I said goodbye to my PCV system.
I'll be running no true PCV valve, but a modified PCV valve with no valve. (see pics)
I cut the very bottom off the stock PCV valve, which exposed the metal valve and springs which fall right out.
Air now flows freely though the uh, un-valve.
Both the valve cover and crankcase hoses will run to a catch can with a breather filter on it.

I'm still deciding whether or not to "Y" the two hoses into the same port and use the 2nd port for the breather valve, or drill and tap a hole in the top and add a 3rd port for the breather filter.
Opinions welcome.

Intake manifold removal tips:
- First thing, assuming you have an air compressor, blow out all dust and dirt away from the manifold and surrounding areas.
You really don't want junk falling into the head.
- Have an extendable magnet handy. Makes reinstalling the bolts much easier, and for grabbing the bolts when removing so they don't fall to unreachable places.
Also great for when you drop the 10mm socket, the 6" extension, or both.
- All the primary 10mm manifold bolts can be reached with a straight 6" socket extension.
No bendy knuckles needed, as I tried to begin with but just made it harder on myself.
- Back out the 2 10mm bolts on the fuel rail at least 1/4". This provides necessary wiggle room to remove the intake manifold.
- Save removal of the knock sensor bolt until after the manifold is unbolted. Much easier to reach.
- Plug the knock sensor electrical connector back in before bolting up the manifold.
- Don't forget to reinstall the little copper tube for the EGR.. unless you just like practice removing and reinstalling the manifold.
Yes I did that. :wallbash:


Intake manifold removed.
The blueish thing near the center of the pic is the PCV valve.

Underside of intake manifold.
The round blue gasket on the far left seals around the EGR port.

PCV valve.
It's possible to remove the valve without removing the black cover, but removing that cover makes it much easier.

Black plastic cover removed:

EGR port. Sans copper tube.
Copper tube must be removed to remove intake manifold.

Back side of black plastic cover with PCV valve installed.

Stock Duratec PCV valve.
The little black plastic retaining ring is a pain to remove.
I managed not to break it, but it's fairly fragile.

PCV valve with bottom cut off.

Contents of PCV valve, in order.

Intake manifold port plugged.

New PVC hose installed but not trimmed yet.
Catch can isn't mounted, so the hose isn't running to anything yet.

Knock sensor.
It's the thing in the middle that's not bolted yet.

- Exhaust
'04 Mach 1. Built. Turbo. 667whp/631wtq
'06 Focus. Built. Turbo. WMI. (sold)
'03 Mach 1 : 12.61 @ 106.59 (sold)

Last edited by sutyak; 09-05-2007 at 10:10 AM.
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