1997 T5 Major PCV Fail, pinched bracket, cam sensor wiring Topic is solved

T5 Tony · Post by **T5 Tony** » 25 Nov 2016, 19:16

So last weekend I decided to begin getting my newly purchased baby to stage zero. First on the list was a PCV replacement, the dipstick was smoking and she blew a glove up like a balloon. I'm a long time MVS site lurker, and I've faithfully read just about every thread on this topic so I felt confident this was something I could achieve myself. I was wrong. I ordered the kit from FCP and followed the video step by step. But once I was done - nothing. So I did it again. And then I took everything apart and reassembled it on Wednesday, Thanksgiving Day, and again today after work. My 850 cranks and turns over, then the rpms shoot to 3500 and she sputters and dies. Won't hold an idle for anything. I thought at first there must be a vacuum leak, but as stated I took it all apart and slowly put it together again 3 times, painstakingly and get the same result. I'm demoralized, frustrated and riding the bus. I just don't know what to do or how I failed. She was running like a champ the entire 2 weeks I owned her before deciding I could do this myself. Now I regret even trying...I'm sorry for the sad noveletta here, but please - can anybody help me?

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Post by **Ozark Lee** » 25 Nov 2016, 19:28

Pretty much has to be a big leak at the intake manifold but you carefully took it apart and re-assembled. Did you take the throttle body off? Did it get a new gasket if you did?

Without seeing the car it is tough to diagnose, perhaps we have a member in your neighborhood that could stop by and take a peek at it with you. Other things to check are the vacuum tree (I cracked on while doing a PCV job once) and the lines that go to it.

...Lee

Post by **shaker_chi** » 25 Nov 2016, 19:39

Check all your turbo hoses while you are at it. Post a video if you have a chance. Good luck.

Eddie G

T5 Tony · Post by **T5 Tony** » 25 Nov 2016, 20:02

A major leak is what I've been searching for, but I can't seem to locate one. I'm positive the tree is intact and the 2 lines running to it are as well. The manifold gasket that came in the kit seemed a tad large to me, but as far as I can tell it's flush. I did notice a split in the ptc gasket, but could that be the source of my issues? I'm afraid I also got "help" from my mechanically uninclined father on days 1 and 2, and I think a bolt on top of the manifold was stripped. I did wrap the bolt in thread tape tonight, but no changes. Totally demoralized. One question though - is there a missing bolt on top? The video (I think) showed them removing 3 on top of the manifold, as I did and 4 on the bottom. But on the top drivers side next to that tabulated grommet (? Not exactly technical, I know) there is a bolt hole with no bolt. Tonight I tried to see if a manifold bolt would fit in it, but it was too long. Am I missing something? Would this possibly give me the results I've had?

T5 Tony · Post by **T5 Tony** » 25 Nov 2016, 20:05

Check all your turbo hoses while you are at it. Post a video if you have a chance. Good luck.

I did check all 3 three lines from the turbo hose and they look a little worn, but no rips or holes. I can try going back to take video tomorrow or Sunday...I live in the city with street parking on a very busy road, so I took the car to my parent's house to use their driveway and they are 30 miles away from me.

T5 Tony · Post by **T5 Tony** » 25 Nov 2016, 20:10

@ Ozark Lee
Didn't remove the throttle body at all...are there any members in Baltimore (where I live) or Harford County, MD (where my car lives now)?

Post by **abscate** » 25 Nov 2016, 21:27

That bolt hole with no bolt is leaking massive air into cylinders 4 and 5.

I think that bolt also holds the vacuum hose carrier which will probably make it right length

T5 Tony · Post by **T5 Tony** » 25 Nov 2016, 23:28

How obvious!!! I'm kicking myself for leaving a threaded hole open; why on earth would anyone design such a thing. I'm going back first thing in the morning, and will report back with my results and/or a video. Thank you!!

Post by **rspi** » 26 Nov 2016, 05:52

What car do you have? Does it have EGR?

beigg · Post by **beigg** » 26 Nov 2016, 06:11

Make sure the bracket that is underside of intake near the TB is not being pinched. If it is, it'll created a nice source to a vacuum leak... If you have not tweaked or cracked the manifold from the torquing unevenness.