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**IMPORTANT** Inlet manifold failure in graphic detail

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334K views 829 replies 245 participants last post by  Communist  
R
#1 · (Edited by Moderator)
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#3 · (Edited by Moderator)
Good post,shows in graphic detail what can happen.
I have the rattle over 3 and 4 ports,i've listened to em with a screw driver,stick one end on the manifold the other end in yer ear hole,you can decide which end goes where. :}

THIS SHOULD BE MADE A STICKY ASAP :idea:
 
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#5 ·
The same happened to me with No1 cylinder, it bent the spark plug. Now I'm stuck with £7K Welcome Car Finance on a knackered 51 2L Ghia X.

I put another maifold on and have been driving it. It knocks upto 1500 revs at No.1 cylinder, I think the little end has gone.

It's only been doing 24 MPG and has been missing and hunting. Now it won't tickover at all. The sparkplugs are black, so it's running rich.

The scum at Ford knew all about this manifold problem. They sold an upgrade for it so they knew. They should have done a recall but the rip off merchants knew that, although the problems start straight out of the factory, it would take long enough for them not to be responsable under the Sale of Goods Act.

My argument is that as the fault occurs immeadiately after sale then they are in fact responsable. They have been grossly negligent and deliberatly ripped us off. Just because the final fatal act of the fault occurs long after the sale does not absolve Ford.

It can be seen by the extent of the wear and tear to the manifold before actual failure, that it takes many 1000's of miles for a fatal breakdown of inadequate componets to occur.

But what can I do. Ford Scum have basically finished me. I've been to Watchdog, Trading Standards and the Arthur Daily's that sold me the car ( who have now gone bust). Welcome Finance just say pay us the finance.

I'll probably just block the gates at a Ford Scum dealers wiv it, go bankrupt n slit me fucin wrists!
 
G
#6 ·
For me, I got lucky.

The flaps did not break, but the bars were a little bent, and the inlet bits around them were very loose. With the new item, no more rattling + I got my low end back which was non existent with the knackared manifold, making leaving junctions fun.
 
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#7 ·
Hello, I´m a new member from Sweden, owning a 2,0 litre Ghia from year 2001.

As far as the inlet manifold is concerned, I was really lucky. During the 120.000 km service, the mechanic detected the rattle which I myself never had heard. Of course, the inlet manifold was replaced and the old one didn´t look very nice....Obviously, I wouldn´t have had too many miles before disaster.

I was informed that this problem is well known and that Ford have come up with new and improved inlet manifolds
 
C
#9 · (Edited by Moderator)
I wish I'd known!!! Mine's only done 57000 and it rattled for about 5 seconds last year on holiday after a blast down a German Autobahn (legal 100+!! cruising). Pulled in for the night and went to a fast food place. Came out, started up and it sounded like the loudest popping of bubble wrap you can imagine - then went quiet and ran perfectly. I went on to Croatia and Bosnia (another 2000 miles all told), returned and drove around normally until about Jan, when it suddenly started to sound like a valve had dropped out on no2 pot. I'm guessing, now I know the weakness, that some heavier metal bits had now followed the butterflies up the spout. I had Ford engine insurance, so took it to the Ford dealer, who said it must be little ends. Yeah, right. They wanted me to guarantee (part of the insurance small print) £1000 labour (not a missprint - £1K) to 'investigate' by removing the engine and taking out the crank etc. If the little ends weree gone, and if the cause was 'warrantied', then I'd get my money back, plus repair. If not ... they never really explained. Rip off merchant or what!!! I work in our local College as a lecturer in the Motor Vehicle Department, so off came the inlet as soon as I found out the probable cause. Now we're in for a BIG argument, maybe a new engine and accusations of (as I hinted at politely when I refused them permission and fetched my car back) - incompetance. One of our lecturers does work for trading standards and says there's no actual PROOF of rip-off attempt so I can't get heavy, even though everybody in the trade would nod sagely. I have permission to take it to an engine specialist to evaluate, report fairly to the insurance and possibly repair, so I'll let you know. Anybody else been here?
 
M
#11 ·
Hi,

Have just had the manifold on my 1.8 petrol mk3 replaced. I kept the old part so I could see the problem for myself.

On mine, the runner and swirl plates were all intact but, while the play of the runner in its bearings was minimal at the end near its vacuum actuator, it had approx 2mm of play at the other end. The wear on those bearings is pretty easy to see.

For info, my manifold was noisy at the leftmost end (near washer bottle). It was intermittently tappy on tickover and usually quite tappy while the engine was slowing down after blipping the throttle.

MarkSpace.
 
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#13 · (Edited by Moderator)
I wrote to Ford about mine, I actually get a phone call from them!
To condense a long and polite call to it's essence, 'It's out of warranty, get lost'..

I also sent the info to BBC Watchdog, I get the impression they are collecting info on the breakdowns.

The most interesting bit of info was re. Mazda's inlet manifold problem..

After seeing a mention on here that implied the Duratec engine is actually a Mazda design (and parts are interchangeable), I searched for info on Mazda manifold problems.

It appears the equivalent Mazda engine had problems with bits falling off the inlet manifold (screwed-on butterfly plates?) but in their case they issued a recall..

ps.
http://media.ford.com/newsroom/release_display.cfm?release=9358

A 2001 article I found about the features of the New Mondeo. This claims Ford engineers invented the swirl plate idea, which is a bit off if it's a Mazda design?

They also called the swirl plates 'Tumble flaps', which seems a bit of a strange name - unless the designer had premonitions of what they would eventuially do?
 
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#15 ·
Listen for rattling at the inlet manifold at idle.

However, I *think* you'll be OK on a 53 plate. See my research - in the end, I had the conversion done on the old manifold, and the converter didn't report any random chunks of metal falling out.
 
C
#16 · (Edited by Moderator)
Yes - stuff 'em. I've bought a new Vectra 1.9tdi - 150hp, 136 mph, 0-62 in 8.9 and for less than £12k on the road with a full tank!!! Faster than the new Mondeo, more power, better fuel consumption and £5k less. It cruises effortlessly at 110 - 120 and I got it up to 142mph on the German Autobahn near Cologne in July (legally!) on a quiet Sunday morning. There was a bit to go but I chickened out! I've been arguing with Ford Protect about the extended warranty on the Mondeo and have won - they admit this is a build/design problem. When it's done, I'm getting rid. I took it to a local, well respected engine specialist and they diagnosed and proved the point in about two hours.
 
S
#17 ·
i have a 2.0 ghia x 02 plate which has just gone in a big way,same as everyone else, inlet let go and bang engine a goner,although my mechanic says (in his beSt 6 million dollar man voice) i can rebuild it,which means crank regrind new pistons shells,valves, the whole caboodle for a nice price of £2000... now then do i have it done or not????????
and all this headache cos the ford monkeys never had the cahooners to do a recall..THANKS FORD....
 
R
#18 ·
I'd be tempted to look for an engine out of a (newer?) write-off, it should be far cheaper...

Just check the electrics are the same to keep things simple.
 
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A
#20 ·
rajenkins said:
I'd be tempted to look for an engine out of a (newer?) write-off, it should be far cheaper...

Just check the electrics are the same to keep things simple.
Click to expand...
When looking for a new engine make sure you get the engine variant right and all the rest will be the same.

The engine variant is hard stamped on the bell housing flange and should be visable by looking down from the top of the engine where the gearbox bolts on.

I think for the 2l petrol it's CJBA, but you best check as this is vitally important.

When phoning round for a replacement engine make sure you quote the engine variant to ensure like for like replacement that will be compatiable to the cars ECU / electrics etc etc.
 
R
#21 ·
I've just got hold of a inlet manifold from supposedly a '06 car but its actually dated
12 - 19 - 00

The part code according to it is:
157 G9E9 26JA
Shift 2ST

Can someone check to make sure the part is from a facelift or newer model please?

The flaps seem to be in ok condition - only a very tiny amount of movement in the flaps- the long steel connecting screw has no movement sidewards.

Many thanks guys for bringing this thread to mine (and others) attention. I too had Ford service my car for its entire life- not taking it to there again!
 
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D
#22 ·
I have had a tapping rattle sort of noise for a while now and after reading this thread I think this is the problem. I have done the screwdriver to ear test and like some others here it is more noisy on the left side of the manifold by the washer bottle. Ford have quoted £175 +vat to supply a new one. What I was wondering is could I take of the manifold and just remove the flaps and then refit it?
 
J
#23 ·
Had my inlet manifold fails last week, took the manifold off and found only 3 of the flaps and missing about an inch of bar. This weekend I have removed the head and found lots of damage to #3 piston crown and the head found out i can get a second hand head for £40 but not sure if its a viable option to change the piston as the bore seems to be free of damage. any advice or should i just go for a replacement engine 1nstead :angryfire: just seem to be another victim of FORD rip off tactics - they wanted $500 just to investigate the fault.

2002 Mondeo LX Est 194,000 miles
 
#478 ·
Because I'm knew to Mondeo's I naturally thought I had dropped a valve, but now I know it was the flaps. I took the inlet off and one bar fell out. Looking at the flange the other flaps and bars were nowhere to be seen, so I would imagine it won't make much difference to the running as the ecu will probably compensate, but it might make a difference to economy? maybe
Image
 
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#25 ·
dazzaman said:
I have had a tapping rattle sort of noise for a while now and after reading this thread I think this is the problem. I have done the screwdriver to ear test and like some others here it is more noisy on the left side of the manifold by the washer bottle. Ford have quoted £175 +vat to supply a new one. What I was wondering is could I take of the manifold and just remove the flaps and then refit it?
Click to expand...
I was just wondering the same thing - does anyone know if these flaps can just be removed? First time I've even heard of them if I'm honest but I've got a rattle myself on my 51 2.0 ghia and am expecting to find the same thing tomorrow :sad:
 
#26 ·
Yes, but then you need to seal up the holes and you'll have a rough idle. Although it's a bit of an expense, you're better off fitting a new manifold and associated parts if you do have the symptoms.
 
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