Mondeo (mk3) - Swirl flap removal

Cona

Hello
I had two problems with my 1.8 petrol Mondeo 2005. First, the car was revving up to 3K revs and idling high. I diagnosed this as the PCV hose needed replacement. The car also developed a bad rattle which I think was the swirl flaps starting to come loose. Both these issues are well known on this Mondeo so I decided to tackle this myself.

So I removed the inlet manifold and took off the PCV hose and found it was indeed ripped in multiple spots. I patched the holes and put the hose back on.

I also took out the swirl flaps. I just took out the actual flaps and left the plastic casing that they sit on on top of the rubber gaskets. I also removed the long metal rod that operates the flaps. I then sealed the hole where the rod inserts with Araldite.

Put everything back together and prayed for luck. Unfortunately, it didnt work and I need help before sending to garage.
Now, on starting it revved up to 5-6K revs (which is very high) and settles down then to about 2.5K. There is almost like a hissing noise also. To me it seems like there is somehow an even bigger vacuum leak with the inlet but I am unsure where or what it might be.


Possible causes:
- I wrapped the PCV hose in Fixx-It tape which I am pretty sure sealed the hose very well. Only thing is that the diameter of the hose is probably a bit tight. However this is unlikely to be taking in air, so probably not the cause? Is it possible that a restricted air hose would cause this issue?

- Sealing the hole where the rod inserts with Araldite...I am not convinced that this hole is fully sealed. I wasnt sure the purpose of sealing this was trying to achieve. Could this possibly be the cause. See from 9:30 mins in this clip to explain what I mean
https://www.youtube.com/watch?v=amRXA22ofds


If anyone has any wise words or suggestions I would be very greatful. I am not far away from admitting defeat and asking a mechanic to take a look but I have given a good few hours to this it would be nice to finish it off.

thanks!!!

rex-x

It sounds like you now have a huge vacuum leak somewhere.

Cona

rex-x wrote: »

It sounds like you now have a huge vacuum leak somewhere.

Ya I think so. I'm trying to locate it now. Trying to figure out if it's the PCV hose or the end of the swirl flaps....

I'm going to have to order a new pcv hose. And then properly seal the end of the manifold where I took out the metal rod.

Hopefully there isn't another place that the leak could be coming in

mullingar

Get a can of hairspray or deodorant and spray around inlet manifold in different areas, in bursts, if you get a rev increase, you found your big leak.

Guy:Incognito

Considering the price of the pcv hose being fook all in the grand scheme of things, it seems madness to do all the stripping of the manifold only to try patch it and risk it not working rather than replace it .

I gave up on the mondeo a week or two after replacing the pcv when it started rattling and nearly cutting out.


Though in fairness, it was also burning as much oil as petrol too

case_sensitive

I had the swirl flaps in my Alfa 159 neutered; but AutoLusso TIG welded the holes closed, would seem to be the only way to do it properly.
Definitely check the price for a new PCV hose though, patched hoses are no bueno.

The other thing you might consider is ditching the existing routing and send that horrible gunk to a catch can; oil and water blow-by being sent back into the intake after the filter is madness, it's astonishing that most production cars still do it.

This is my Zetec-engined MEV Rocket set up
http://mevowners.proboards.com/thread/3946/rocket-st159?q=PCV

Cona

Thanks for the replies. Rang Ford direct and they want 55€ for a new PCV. Crazy!! So I measured the diameter and it's 15mm. Rang a local motor factor and he has some rubber fuel pipe that I going to take and see if it works.

As I had spare time today, I removed the manifold and took off the hose. Looks like I repaired it a little too well as I think it was after blocking itself. So fixed it properly and put it back on. The good news is, the revving and idling is after settling down and it seems to be idling nicely now. Only problem is a knocking noise coming from something. I think this was happening before as well and I thought it was the loose swirl flaps. They are removed but I still have a knocking...

Does anyone know if I have to remove the bushing as well?? It's not obvious where they are or how to remove them but I saw them in the YouTube video so possibly they are doing the knocking...

Oh, I dropped the last inlet bolt into the bay and couldn't fetch it out. Might be the culprit but I highly doubt it...

tcawley29

Cona wrote: »

Thanks for the replies. Rang Ford direct and they want 55€ for a new PCV. Crazy!! So I measured the diameter and it's 15mm. Rang a local motor factor and he has some rubber fuel pipe that I going to take and see if it works.

As I had spare time today, I removed the manifold and took off the hose. Looks like I repaired it a little too well as I think it was after blocking itself. So fixed it properly and put it back on. The good news is, the revving and idling is after settling down and it seems to be idling nicely now. Only problem is a knocking noise coming from something. I think this was happening before as well and I thought it was the loose swirl flaps. They are removed but I still have a knocking...

Does anyone know if I have to remove the bushing as well?? It's not obvious where they are or how to remove them but I saw them in the YouTube video so possibly they are doing the knocking...

Oh, I dropped the last inlet bolt into the bay and couldn't fetch it out. Might be the culprit but I highly doubt it...

Maybe drive forward about 1m or so and slam the breaks (in your driveway). You may get lucky and it may find its way to the ground. You don't need speed to do this