hi all, well as f1 was on this morning i knew my mum will be waking me up, so i through i get cracking on the duratec.

so throughts were, clean teh engine, take the bits i do not want on it off, and make a blanking plate for the egr port,

so started cleaning it, one side then i finshed taht side, and through i will take the inlet maniflold off, and my dad came in the grarge and gave me a hand.

engine
so took the manifold off, and look what i found:

inlet manifold
one off the buterflys is missing, and they are conneted with a steel rod.

i found the buterfly, it was resting on teh vaule, as it was to big to do through the vaule:

and why

and this is where it came out from:

here it is

so we took the spark plugs out, put a magent down there and did get a few metal filings.

so then we turend the engine up side down, and nothing came out, then enough round with the magent, nothing at all.

so we throught lets try and look at the piston and cylinder through the vaules, and yep the cylinder is scoured, but not sure how bad yet.

so we through a compression test woudl be a good thing to do, but i have no flywheel, so with all the plugs out and fitting one at a tiem to differnt cylinders and turn the engien over by hand the promblem cylinder has a lower compresion, and then we put oil in to the promblemed cylinder, and it felt simlar to the others compression.

but i did find a pices of the steel rod, crused up, in the inlet manifold, so they was in the cylinder, and came out the inlet not the exhaust, and a pice about 2inch long as well, but not sure if that went in or not, does not look like it did.

so any throught of why the steel rod which goes through teh buterfly whould have broke?

any idea's which is teh best way to fix it?

cheers

staurt

looks like the best thing for you to do is take the head off and have a good look in the bore. don't know if its just the lighting in the last photo but is that valve bent?

hope it isn't too bad?

Common problem with the Duratec engine , have change several manifolds due to this happening. Anyone buying a Duratec engine should try to hear it running, ANY noises from the manifold indicate the secondary butterflies/shaft have wear

i do not think the vaule is bent, but not sure in teh whole state, as i am realy trying to look through a small hole.lol

i did not know that was a common promblem. dam

stuart

Only way to find out is have the head off.

Unless you know anyone with a bore scope?

If the bore is knackered and you are fitting forged pistons oversize ones are easily available.

David

do you know what compression teh cylinders should be?

and are 88mm pistons standard or oversized, by 0.5mm, as i think the standard piston is 87.5 or something like that.

thanks

stuart

Cylinder leakage test might be a good idea? Done without removing the head. IIRC British Trident may have posted instructions for a DIY tester?

i can not seem to find that on here. any links?

cheers

stuart

Std bore is 87.5mm. So 88mm is 0.5mm oversize.

I would take off the head and do a full inspection.
Otherwise i would go around and think about it all the time.

Ford Mondeo Inlet Manifold failure.