I recently replaced the ignition coils in this vehicle per this discussion:
2005 Ford 500 Engine Isssues
After coil replacement, the engine ran great for ~10 days.
Then, nite before last, the owner was on the way home after running some errands and suddenly the engine starting stumbling and running poorly. It progressively got worse and the engine completely died about 1/4 mi from home.
Upon inspection this afternoon, I found a hole in the intake, just downstream of the throttle body (see pic).
The hole is approximately diagonally opposite of the EGR valve.
The hole shows evidence of melted plastic.
The plastic around the hole seems to have been thinned considerably.
Did the EGR valve fail open, allowing a steady stream of hot exhaust to burn/melt the manifold ? ( a re-check seems to indicate that I did not miss anything when I last reassembled the manifold)
I wonder if any bits of plastic were sucked further into the intake, waiting to cause damage to the engine?
Thoughts on what could have caused this?
FYI...I was able to stuff a paper towel into the hole to get the engine to run (barely) to get it the last 1/4 mi home today.
I don't want to jump into this job again without having some idea of the failure root cause.
thanks!
2005 Ford 500 Engine Isssues
After coil replacement, the engine ran great for ~10 days.
Then, nite before last, the owner was on the way home after running some errands and suddenly the engine starting stumbling and running poorly. It progressively got worse and the engine completely died about 1/4 mi from home.
Upon inspection this afternoon, I found a hole in the intake, just downstream of the throttle body (see pic).
The hole is approximately diagonally opposite of the EGR valve.
The hole shows evidence of melted plastic.
The plastic around the hole seems to have been thinned considerably.
Did the EGR valve fail open, allowing a steady stream of hot exhaust to burn/melt the manifold ? ( a re-check seems to indicate that I did not miss anything when I last reassembled the manifold)
I wonder if any bits of plastic were sucked further into the intake, waiting to cause damage to the engine?
Thoughts on what could have caused this?
FYI...I was able to stuff a paper towel into the hole to get the engine to run (barely) to get it the last 1/4 mi home today.
I don't want to jump into this job again without having some idea of the failure root cause.
thanks!
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