Galaxy 2.0 Tdci Inlet Manifold Problems

[wheelie1]

Hi All.

 

Can anyone help with the following problem ? I have a 2008 16000 mile Galaxy.When the engine is turned off two issues are noted, the first being vacuum is heard to be bleeding out from the inlet manifold area ( almost like a person belching )and the second being the inlet manifold is being sucked in ( sharp thud heard from manifold area / flap )

 

There is no reduction in the cars performane on the road.

 

The local ford dealer has replaced the two red electro / vacumm solenoids above the clutch housing but the problem still persists. The EGR valve was changed under warranty about 8 weeks previously for black smoke / soot which the car has displayed from new, this was only on small throttle inputs when engine is first under load.

 

The dealer has now replaced the EGR valve again but still have the issues with the inlet manifold / vacuum components.

 

Can anyone please suggest what is causing this problem ??

[buford_t_justice]

At last someone else who can report a similar problem as me!

 

I have had this issue on my car for nearly 3 years! The dealer is unable to replicate the fault and has not heard of it before. The belching noise you hear (which starts loud and fades away to nothing) I get after the engine has been turned off but not always and not at definite times. I may occur after a 30secs or maybe 3 or 4 mins. I asked the dealer to investigate what processes take place after the engine has turned off to narrow this fault down but I think I was getting my hopes up on that one!

 

Please let me know if you find out what it is as the dealer said they would fix it for free because I had reported it during the warranty period but could not find the fault during this time.

Edited July 7, 2011 by buford_t_justice

[wheelie1]

I would suspect this problem effects more vehicles than just our two ! The situation at present is basically Ford Technical support appear to be off little help to my dealer. I have managed to establish, all be it second hand from another dealer, that the loud thud that is heard when the engine is stopped is a process that allows air into the inlet manifold via the electro / vacuum solenoids above the clutch housing to snap shut the inlet manifold flap to ensure the engine shuts down quickly when you turn the key off. What appears strange that depending on the car ( Any vehicle with 2.0 Litre TDCI PSA/Ford engine )the noise created from this flap closing varies greatly from engine to engine.

 

Yesterday I have through my own reaserch ! heard a 59 plate Galaxy make no noise at all and a 58 plate S-Max create a muted flap closing noise when the engine is stopped.

 

As I type this update no one has come up with a solution for the vacuum bleed noise which happens, but again not on every engine shut down. This apart from yet another dealer who said change both red solenoids and that will sort problem !! It did'nt.

 

Watch this space as car is waiting for dealership Master Tech to sort on Monday.

 

On a closing note I find it difficult to believe that with all the Ford vehicles around with this very same engine installation in, Ford Technical can give no advice at all to the dealership network

 

 

Maybe all of our readers should open the bonnet tonight and have a listen when the key is turned off.... LOL

[buford_t_justice]

Any news following last Monday??

[wheelie1]

Hi All

 

No Luck yet. The garage tried I believe various components from another vehicle. So far I have not heard any vacuum bleeding away as before, but still get the distinct noise from the manifold area when the engine is stopped.

 

No one can seem to give a reason for this so far.

[wheelie1]

UPDATE......

 

I have now totally given up on dealers for this issue !!!Evidence suggests most are of the 'make it up as you go a long brigade' Self help prevails.

 

I have now discovered an intercooler pipe to the manifold had a very loose hose clip to the extent that oil was leaking from the front valance below the intercooler on the offside of the car.

 

I also isolated the vacuum pipe on the inlet manifold flap actuator and guess what ??? No noise at all. To double check I then re-connected the vacuum hose started up, placed a large screw driver to my ear while the blade rested on the manifold flap housing, without doubt this is where the noise is.

 

Now for the big question ?? is it the manifold flap and / or vacuum actuator at fault, maybe, but Ford want

[buford_t_justice]

I had high hopes when I spotted you had replied but alas!

 

Mine is due a quick oil and filter change shortly so when it's in the garage I will mention for them to take a look at the manifold flap and vacuum actutator as a possible source of the noise I pointed out to them several years ago! I won't be paying for any repairs that's for sure.