FCV stuck open now

Tinman · **Joined:** Mon Apr 10, 2006 10:45 am **Posts:** 308

I posted a while back about a no start condition that was the FCV sticking closed. I disconnected it and we got it to the dealer. They apparently cleaned it and ordered a new one to replace the current one. That was a while back and we've not heard anything. I didn't care because it's not functional now anyay (ORM). The dealer plugged it back in and I left it that way to close at shut down. Well, the other day my wife said the truck was making an awlful sound at shut down for about 10 seconds. She thought it was the ax. fan but when I finally got around to looking at it, it was the FCV buzzing loadly. I guess it is stuck open now and the little motor/actuator is going crazy trying to shut it. I unplugged it and all is quiet. I guess we'll go to the dealer now and make them replace it.

CATCRD · **Posted:** Thu Nov 01, 2007 11:22 am

Mine has stuck open too at 24000 miles. I noticed severe engine shake on shutdown, and a louder than usual buzzing continue from the FCV for 10 seconds. There was no crisp click either after the buzz stopped like there used to be. No other symptoms while running, still getting good mileage. Have been running the ORM since 19000 mi.

To anyone who has checked, when you pop the intercooler hose off the FCV, can you move the plate by hand? Mine is really stuck.

Forgot to say, been running the EHM since 9000 mi.

dgeist · **Posted:** Thu Nov 01, 2007 11:26 am

Tinman wrote:

I posted a while back about a no start condition that was the FCV sticking closed. I disconnected it and we got it to the dealer. They apparently cleaned it and ordered a new one to replace the current one. That was a while back and we've not heard anything. I didn't care because it's not functional now anyay (ORM). The dealer plugged it back in and I left it that way to close at shut down. Well, the other day my wife said the truck was making an awlful sound at shut down for about 10 seconds. She thought it was the ax. fan but when I finally got around to looking at it, it was the FCV buzzing loadly. I guess it is stuck open now and the little motor/actuator is going crazy trying to shut it. I unplugged it and all is quiet. I guess we'll go to the dealer now and make them replace it.

Yep, thankfully with your EHM, you shouldn't need to do it again. Out of curiousity, was your CCV bypassed the entire time since they cleaned it? If so, I'd be surprised that it got stuck (as very little's going to to stick it...).

Dan

Tinman · **Joined:** Mon Apr 10, 2006 10:45 am **Posts:** 308

CCV has been bypassed for >15k miles. ORM for about 12K miles. Rig has about 26K now. I doubt the dealer did much and it was gunked up pretty bad when I was sticking closed. So it probably had enough stuff in there to cause the problem. Could be the motor in the FCV finally crapped out b/o the increase effort of closing the valve against the crud.

Sir Sam · **Posted:** Thu Nov 01, 2007 2:41 pm

CATCRD wrote:

Mine has stuck open too at 24000 miles. I noticed severe engine shake on shutdown, and a louder than usual buzzing continue from the FCV for 10 seconds. There was no crisp click either after the buzz stopped like there used to be. No other symptoms while running, still getting good mileage. Have been running the ORM since 19000 mi.

To anyone who has checked, when you pop the intercooler hose off the FCV, can you move the plate by hand? Mine is really stuck.

Forgot to say, been running the EHM since 9000 mi.

no engine shakedown noise, but a buzzing sound, at about 39000 its died, no hurry to replace it, jeep still runs fine.

Goglio704 · **Posted:** Thu Nov 01, 2007 3:14 pm

CATCRD wrote:

Mine has stuck open too at 24000 miles. I noticed severe engine shake on shutdown, and a louder than usual buzzing continue from the FCV for 10 seconds. There was no crisp click either after the buzz stopped like there used to be. No other symptoms while running, still getting good mileage. Have been running the ORM since 19000 mi.

To anyone who has checked, when you pop the intercooler hose off the FCV, can you move the plate by hand? Mine is really stuck.

Forgot to say, been running the EHM since 9000 mi.

On a healthy FCV you can move it by hand. It is spring return to the open position.

flash7210 · **Posted:** Thu Nov 01, 2007 3:31 pm

What about removing the butterfly from the FCV. There should only be
two screws holding it on. They are probably locktite-ed so it may not be
easy to do.

dgeist · **Posted:** Thu Nov 01, 2007 3:36 pm

So, it sounds like the increased drag on the FCV motor might cause problem long after removing the source of oil input. What's the safest way to clean the valve? MAF cleaner? Soak the butterfly for a few hours in B100? I don't want to have the nasty stuff come back to haunt me when I'm out of warranty. Professional oppinions appreciated...

As an aside, is there a straightforward way to clean the intercooler (same reasoning).

Dan

Spowers · **Posted:** Fri Nov 02, 2007 8:06 am

Mine started that exact thing over Memorial weekeend this spring.

I did check it out, it is not stuck, I can close mine by hand, then when you power up the system, it will open nicely untill it reaches full open, it will then begin to flutter. I cleaned mine with some carb cleaner, then sucked it out with a old shop vac.
It still did it,

It will get worse, It will start with only a little flutter after shut down, then it will begin cycling as you drive. the longer it goes, the more frequenst the flutter becomes.

It is as if someting in the servo motor is going out.

gmctd · **Posted:** Fri Nov 02, 2007 10:26 am

As you know, the only way to clean a charge-air cooler is to remove it, same with Ford, GM, DCX, and all the rest - use diesel fuel or kerosene or varsol or paint thinner, then heavy-duty detergent, as in drive-way cleaner - the inlet\outlet tubing is at the every top of the end-tanks - needs to be 1/4 filled, sealed, sloshed several times to allow the cleaner to remove the gunk from the bottom tanks and tubes, drained - once more 1/2 filled to be sure the lower area is clean - once more 1/2-filled, rotate 180deg, do the top area, slosh several times, drain - then, flush and rinse with the garden hose - 140-180deg hot water works best, here, for quick-dry - stand on either end to drain and dry

And, be careful - those are thermo-plastic end-tanks crimp-sealed to rubber gaskets on the aluminum heat-exchanger, just like on your engine-coolant radiator and the heater-core

Sir Sam · **Posted:** Fri Nov 02, 2007 1:59 pm

I think we need an upgraded intercooler option, why clean when you could upgrade!

msilbernagel · **Posted:** Fri Nov 02, 2007 4:35 pm

Just had mine replaced - tech's notes said "EGR sticking and tuning valve not operating all the way".

They also replaced the fuel cap, evidently stuck open.

The slight bumping/miss at 55MPH when feathering the throttle is gone... since we bought it used at 29,500 miles (42k now) it's had that - so my guess is that the things were sticking long before they finally went.

Mark

Diamond Cut · **Posted:** Sat Nov 03, 2007 1:04 pm

The charge-air cooler upgrade is ~1200bucks from Banks and such - gallon of paint thinner is ~7bucks, jug of detergent for grease'n'such is ~7bucks........................

Still me

onthehunt · **Posted:** Sun Nov 04, 2007 9:31 pm

I have had very good cleaning results with cascade dishwasher detergent. Excellent degreaser and it rinses out with water very easy.

gmctd · **Posted:** Sun Nov 04, 2007 11:18 pm

That'll work - it's just sooty crankcase oil - 140deg and good detergent

blake1827 · **Posted:** Mon Nov 05, 2007 12:59 am

What are the FCV & EHM? I'm guessing the FCV is a flow control valve coming off the radiator/charge air cooler? but where is it? pics please?! What is the EHM mod?

Cowcatcher · **Posted:** Mon Nov 05, 2007 2:36 am

Elephant Hose Mod, venting the CCV to open air.

dgeist · **Posted:** Mon Nov 05, 2007 3:21 pm

blake1827 wrote:

What are the FCV & EHM? I'm guessing the FCV is a flow control valve coming off the radiator/charge air cooler? but where is it? pics please?! What is the EHM mod?

FCV sits at the end of the "cool side" of the intercooler hose. The hose is clamped onto it and it's just inboard, behind, and below the negative battery block lead on your battery. It's machined aluminum and has a grey plastic motor housing on the top of it with a plug for the wiring harness. It almost looks like a single barrel carb laying on its side in the intake path. It's not hard to see in daylight or with a flashlight, but unless you have small hands, getting at it is a little tricky without removing the battery.

Once you have the hose out (which can be slid out with the clamps loosened), you can see in to know how gummed up things are. If you DO need to take it off to clean it, there are 4 5mm allen thru-bolts in the corners. They're not too tight, but are tricky to get at. Take it slow and you won't loose an allen wrench inside the frame rail like I did...

McMoney · **Posted:** Tue Nov 06, 2007 5:46 pm

I have heard the buzz noise all the time when i shut the jeep off. then the sound of the valve opening after 10 seconds. i think the noise is normal. the first time i heard it i checked and i think everything is ok. no problems on shutdown. Have had orm and ehm since 5km and at 30km now.
I have thought of unpluggin it but i dont want a runaway when i shut it off :wink:

dgeist · **Posted:** Tue Nov 06, 2007 5:53 pm

McMoney wrote:

I have heard the buzz noise all the time when i shut the jeep off. then the sound of the valve opening after 10 seconds. i think the noise is normal. the first time i heard it i checked and i think everything is ok. no problems on shutdown. Have had orm and ehm since 5km and at 30km now.
I have thought of unpluggin it but i dont want a runaway when i shut it off :wink:

Yep. That's normal. Shuts completely on key-off, then opens back up in about 10 seconds to allow things to cool-down normally. Someone on the ORM-circuit thread talked about the potential runaway problem and there was something about the electronically controlled injection that would prevent it. Don't remember the specifics, though. I think the FCV closes mostly to ensure that the shutdown is complete but mostly is there to balance flow with EGR operation.

FCV stuck open now

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