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Old 01-31-2017, 06:15 PM   #1
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2005 ZX4 2.0L PCV Valve and Hose Replacment

Hi

I am new to the forum and am the original owner of a 2005 Focus ZX4 2.0L Duratec. I have 207,000 miles on the car and it has been a dependable daily driver for me for a number of years. I am joined the forum to gain knowledge and hopefully get another 200k out of my Focus.

We recently bought a 3rd vehicle, so this will give me an opportunity to do some more major maintenance to it without being under the gun to have it drive-able again by Monday morning.

Other than basic maintenance; oil changes, spark plugs and air filter @140K along with brakes, tires (3 sets) and a battery. I have not had any major issues with my Focus.

Recently it started running rough at idle and did not want to start immediately on the first crank without hitting the gas pedal. I changed the fuel filter and cleaned the throttle body. This helped , but did not fully correct the rough/low rpm idle issue and it still does not want to start without tapping the gas pedal.

Based on posts I've read on this forum, I believe I may need to replace my PCV valve and hose. I understand that I will need to remove my intake manifold to do this. While changing the PCV valve and hose, I would like to perform any other maintenance that would make sense while having the intake manifold off and have all the parts on hand before I begin the repair.

From what I've read on the forum, so far I believe the following items make sense. If you have brand recommendations for the parts to purchase along with any other repairs to perform or parts I overlooked, please let me know.

PCV Valve and Hose : (Dorman, OEM or other?)

Intake manifold gasket: (Brand?)

Thermostat and thermostat housing gasket: (Brand?)

Drive Belt: (Gates)

Idler pulley and bolt ?: (Brand?)

Upper and Lower radiator hoses: (Gates)

Thanks in advance for your help

Jim


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Old 01-31-2017, 10:06 PM   #2
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Hi Jim, I can't help much, but since I did similar work a couple years ago & some other similar stuff recently I will chime in.

PCV Valve and Hose : (Dorman, OEM or other?)
I used OEM, Dorman is fine.

Intake manifold gasket: (Brand?)
I did not replace it, but everyone else hates this idea. The old one was pliable, soft, perfect.

Thermostat and thermostat housing gasket: (Brand?)
I used a Motorad 512-185 Thermostat.

Drive Belt: (Gates)
Gates, ok, why not. Think I used an ACdelco, not sure.

Idler pulley and bolt ?: (Brand?)
I used OEM, only use OEM here. Some might suggest not replacing it, since bolt failure does/can happen after replacement; then again, pulley can fail due to age.

Upper and Lower radiator hoses: (Gates)
I used ACdelco, Gates is good.

Have not had a failure on any of these new parts... yet.

Other thoughts:
Refill coolant with same exact coolant type in use now. I stuck with OEM Gold.

Belt tensioner replacement? This, and other belt stuff can wait, is a different job compared to PCV hose, -the other stuff on your list.

Inspect, clean the inside of the throttle body.

Inspect, clean the inside of the IACV.

Inspect, clean the inside of the intake manifold (IM). To include the IMRC tumble flaps. Careful with IM bolt torque.

Are you still using the original engine mounts? If/when you replace these, stick with OEM.

Good luck!
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Old 02-01-2017, 05:58 PM   #3
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Moved to "General Technical Chat".
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Old 02-01-2017, 07:48 PM   #4
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'Intake manifold gasket: (Brand?)
I did not replace it, but everyone else hates this idea. The old one was pliable, soft, perfect.'

Compare the old gasket to a new one, they can be TOO soft after use and not have the resistance to crush straight down like they must to seal correctly. If too flexible then it sucks the side in to roll it over in what becomes a leak rather than resisting that. The new one while being still flexible has much more stiffness to it to resist that and it helps to create the crush necessary to seal. A softer one has no crush like that.

Just sayin'............not all will do that but I've seen some so flexible no way could they stand up to a negative pressure. Yet in and of themselves look perfect. Without a new one to compare no way will you guess that.
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Old 02-02-2017, 01:46 AM   #5
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Thanks for the replies,

I got my parts ordered for the pcv repair yesterday from RockAuto, hope to have them by mid next week. I went ahead and ordered the gasket kit for the intake manifold at $11 it's not worth taking a chance.

I am going to replace the thermostat and radiator hoses while I have the intake off. I am going to wait on the belt and pulley replacement as suggested.

I have already cleaned the throttle body.

Will need to locate the IACV for cleaning.

On the IMRC tumbler flaps, I've seen some posts where people have removed them completely. My tumbler flaps are pretty noisy. I am still trying to research this to see if it is a good idea for me. Any recommendations on tumbler flap removal?
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Old 02-02-2017, 02:36 AM   #6
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Quote:
Originally Posted by amc49 View Post
...If too flexible then it sucks the side in to roll it over in what becomes a leak rather than resisting that...
Not going to argue this with you. My old gasket was fine, firm, and held into the IM gasket grooves just right. That old gasket was not going to roll into the intake nor create a vac leak UNLESS the IM or head was not flat or the IM bolts were not tight. I would never advise someone to not replace it.

Replace the gasket always, I agree, -minus the job that I did on my car.
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Old 02-02-2017, 02:37 AM   #7
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Quote:
Originally Posted by Plas62 View Post
I went ahead and ordered the gasket kit for the intake manifold at $11 it's not worth taking a chance.
I agree. Gasket replacement (not re-use) is the norm and is the right thing to do.

Quote:
Originally Posted by Plas62 View Post
On the IMRC tumbler flaps, I've seen some posts where people have removed them completely. My tumbler flaps are pretty noisy. I am still trying to research this to see if it is a good idea for me. Any recommendations on tumbler flap removal?
I can't recommend it, and I have never done it.

I believe the flaps are designed to be not removed. Removal require creative deconstruction, -modification.

IMRC rattle noise is typical and unfortunately normal.

Here are some links with additional info about IMRC tumble flap stuff.

http://www.focusfanatics.com/forum/d...ers-guide.html

Warning: The thread below is very lengthy, and has discussion that is wrong or confusing with regard to what IMRC is. For the sake of simplicity IMRC = tumble flaps. -and IMTV tumble flaps is only for the 2.3 engine.

http://www.focusfanatics.com/forum/d...ap-delete.html
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Old 02-02-2017, 03:23 AM   #8
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Thanks Marde for the quick response.

After reading through a few pages of the posts you linked. I think I will leave well enough alone and just clean the tumbler flaps while I have the intake off. Is the CRC Throttle Body Cleaner OK to use for this? I have about half a can left from cleaning the throttle body a couple weeks ago.
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Old 02-02-2017, 10:12 AM   #9
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Quote:
Originally Posted by Plas62 View Post
...Is the CRC Throttle Body Cleaner OK to use for this?
It might be, but is quite aggressive. I was concerned that it might be too harsh for the flaps rod bushings, and did not want to push my luck. I can't remember exactly, but I used Dawn soap + another degreaser mixed in a bucket of hot water. Dumped mix inside the IM, shake-shake; then a toothbrush-like tool on the flaps. Looked ugly in the end, but it helped get most gunk away.

Before cleaning, hold IM upside down, as there might be a few table spoons of oil inside the IM.
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Old 02-02-2017, 10:28 AM   #10
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I took the manifold from my old 2.3 to a machine shop and they hot tanked it. It came out very clean.
As for flaps, I don't remember the 2.0 having them, but staying away from removal is good unless you're into tuning a mod like this. It was an awesome mod but the car didn't like it after awhile because I didn't tune for it.
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