2006 S Max 2.0 petrol inlet manifold - help please?

[GeoITFC78]

Hi all, Iââ,¬â,,¢m after some advice please? Iââ,¬â,,¢m currently in the process of changing my inlet manifold, due to the swirl flaps rocking around, Iââ,¬â,,¢ve managed to get the wiring loom, throttle body etc. Out of the way, I have removed six bolts from the manifold with two remaining (pictured from the engine side, are the two bolts Iââ,¬â,,¢m struggling with) can anyone offer some advice on an easier way of removing these? I ran out of light earlier, but I was struggling to get the socket onto the bolt circled no.1, the no.2 bolt I was able to get the socket on, but had no room to manoeuvre the socket wrench. Iââ,¬â,,¢m at work until Wednesday, so Iââ,¬â,,¢m going to give it a bash in daylight using different socket extensions etc. But Iââ,¬â,,¢m kind of hoping someone on here can give me a simpler method, seeing as Iââ,¬â,,¢ve got to get the done up again!! Iââ,¬â,,¢ll search the forums anyway also. Thanks, Andrew

[johnnyroper]

Never done one but looking at that picture I would say you need to remove other stuff to gain access,I have done BMW ones where access was limited and needed to remove other components. Alternator,belt tensioner etc

[brianh]

Generally the couple of times I've done that sort of job, a combination of extension bars (ideally a wobble type one too) is enough to do it. Not done that particualar vehicle, so as said above its probabbly other bits in the way that we can't see from the photo. Ford usually stick a couple of studs on there which helps when you come to relocate them, usually one either end.

You might find a crowsfoot adaptor to help if its a normal hex head your dealing with - usually the inlet isn't particually tight, so once you get it to move thats the worst bit dealt with, really depends what space you have to play with.

[GeoITFC78]

Thanks for your replies, Iââ,¬â,,¢m giving it a bash tomorrow morning so Iââ,¬â,,¢ll update once Iââ,¬â,,¢ve sorted it (hopefully)

[GeoITFC78]

Right, I managed to change this without removing the power steering pump etc. it was a hell of a job particularly the two bolts, furthest left and bottom looking at the engine. I found using masking tape to hold the bolts on the sockets when rebuilding to be beneficial as Iââ,¬â,,¢d dropped two bolts when dismantling! Only retrievable when the manifold is removed so did not want to do it again! A tip would be replacing the small hoses (vacuum?) before placing the manifold on the engine, I didnââ,¬â,,¢t and the furthest rear was a pig and half to get on.

Unfortunately for me, once replaced I still have a ticking sound which a mechanic has now looked into for me and it appears to be the timing chain slapping the engine. Itââ,¬â,,¢s unknown at this point if the chain has stretched or itââ,¬â,,¢s just a guide rail😟 having done only 62k Iââ,¬â,,¢m worried that a lack of maintenance has contributed to this, and whether to keep the car or not. Awaiting a quote from Ford for a full timing chain kit replacement, as my normal mechanic and a couple of others pull funny faces when I ask😂

[GeoITFC78]

Manifold removed, two hardest bolts circled when putting it back together

[brianh]

Can see from the later pic why you had problems, least you got it done now. Shame it hasn't solved the problem though. cunning way to get around the bolt dropping out problem too.

[johnnyroper]

I would try and find a decent Indy garage as ford will be quite expensive. Donââ,¬â,,¢t understand why they pull faces though itââ,¬â,,¢s just a timing chain. I have done timing chains on my drive before on BMW etc and countless timing belts that are more difficult than a chain on a ford 2.0 diesel. Vauxhall V6, Subaruââ,¬â,,¢s etc.

[mike wilson]

If it's the engine I'm thinking of, the chain just connects the two cams.  It's small and should be quite cheap.  The work to replace it, however....   Would suggest that you will need to do the timing belt and change the water pump when you are in there.

[brianh]

If thats the right engine shown in the diagram on the post above, then it would look like you should be able to see the chain with the rocker cover removed. If it hasn't been removed to investigate, I'd be inclined to remove it and have a look to see if you can confirm whats wrong with the chain (if that really is the source of the noise).

[GeoITFC78]

Is that the 2.0 Tdci engine pictured? My one is petrol, and doesnââ,¬â,,¢t have a belt. Iââ,¬â,,¢ll try to inspect the chain via removing the rocker cover at some point. It sounds like the tappets are quite noisy too, nothing like the old Ford CVH lump, just quietly tapping on tick over.

It flew through its MOT on Monday, so probably worth keeping for now.

[johnnyroper]

Just a thought before taking it apart when was oil and filter last changed?

[GeoITFC78]

Iââ,¬â,,¢m not sure, I bought it off my neighbour, whoââ,¬â,,¢s ex bought it from a local reputable dealer, so guarantee it has history, but I am unable to get hold of this. Wasnââ,¬â,,¢t done that long ago, however Iââ,¬â,,¢m wondering if itââ,¬â,,¢s started to use oil like fuel, which is possibly why it got so low without any signs and maybe done the tensioner/guide rail on the TC.there is slight noise from the tappets so maybe this and piston ring wear has contributed to all of this.  Think it might be cheaper to get a replacement recon engine.

[GeoITFC78]

Itââ,¬â,,¢s only just rolled over 62k

[johnnyroper]

I canââ,¬â,,¢t imagine it has worn rings at that mileage, does it smoke from exhaust?


Personally if it was me I would be taking it apart to diagnose whatââ,¬â,,¢s up first before going recon lump route

[GeoITFC78]

It has occasional puffs of smoke I believe. Itââ,¬â,,¢s using oil, as there is no leaks that I can see. Add to that the noise from the engine, Iââ,¬â,,¢m thinking itââ,¬â,,¢s a ticking time bomb. If I had the time and space Iââ,¬â,,¢d love to have a play about with it. It could be something simple but costly, if itââ,¬â,,¢s a result of neglect and I have the current issues sorted for the price of a new car, whoââ,¬â,,¢s to say the bottom end isnââ,¬â,,¢t going to give up in six months or so? It needs some bodywork doing also, which I can do but would like it to run smoother. It pulls well and drives lovely, just taps like a thousand Ford 1.8td lumps!!

[mike wilson]

Is that the 2.0 Tdci engine pictured? My one is petrol, and doesnââ,¬â,,¢t have a belt. Iââ,¬â,,¢ll try to inspect the chain via removing the rocker cover at some point. It sounds like the tappets are quite noisy too, nothing like the old Ford CVH lump, just quietly tapping on tick over.

It flew through its MOT on Monday, so probably worth keeping for now.

Sorry; complete and utter brain fade.

[mike wilson]

All the images I can find of the EW10 show a belt.