How to restore intake manifold and swirl flaps Ford Duratec 1.8, 2.0, 2.3, 2.5

• falling dynamics;
• high fuel consumption;
• omissions of ignition at idle speed;
• impaired sparking.

To get rid of these negative moments, and without additional air supply, the engineers used swirl flaps, which not only reduce the cross-section of the intake manifold channels but create a certain directional vortex airflow.

By changing the geometry of the intake manifold at low and idle speeds, it was possible to improve the ignition of the mixture, as well as make the exhaust less toxic, as the fuel now burns completely without overconsumption.

Design and malfunctions of the collector geometry change system

Swirl flaps are made of plastic and fixed on a steel axis of the square cross-section. The area of the damper is smaller than the cross-section of the intake manifold, so even in the closed position, the petals do not block the air supply.

The axis of the swirl flaps is driven by a vacuum membrane unit mounted on the intake manifold controlled by the IMRC valve. Vortex valves are closed when the engine is stopped and idling.

Signs of malfunction or wear of the system of changing the geometry of the intake manifold of Duratec engines on Focus, Mondeo, C-Max, S-max:

• Rustle, “diesel”, and in the later stages of wear a loud crack during engine operation. Noise is very similar to the sound of unadjusted valves.
• Accumulation of oil emulsion in the collector, vacuum membrane tubes, and on the IMRC valve.
• High fuel consumption, sometimes up to 12-13 liters per hundred km, depending on engine capacity.
• Slight drop in traction, dynamics, unstable idling, and many other similar symptoms.

The service life of swirl flaps depends, rather, on the operating conditions of the engine and is from 3 to 5 years.

In running cases, the plastic blades wear out so much that they can be destroyed and fall into the gas distribution mechanism, which is dangerous.

It is easy to check the wear of the damper axis. To do this, simply remove the vacuum hose from the IRMC valve with the engine running, then plug the hose with your finger. Noise will disappear, which indicates the wear of the vortex valves.

On Ford Mondeo cars with a Duratec engine, the dampers can be replaced, and the intake manifold of the Ford Focus is made in a slightly different scheme. Here replacement of blades is not provided, therefore at critical wear, it is necessary to change all manifold in collecting. The thing is not cheap.

A new OEM intake manifold with catalog number 2100040 for a two-liter Duratec, for example, costs $280. Used can be bought for $150, but not the fact that wear there will not be critical.

Therefore, the repair of the intake manifold on these engines sooner or later becomes relevant for every driver.

How to repair the intake manifold Ford Focus, Duratec 1.8, 2.0, 2.3, 2.5

Repair of swirl flaps involves the installation of bushings in the housing of the intake manifold. Alternatively, they can be replaced with bearings of appropriate diameter (11.6×5 mm, outer and inner diameter, respectively), but in most cases the sleeve is a reliable, inexpensive and affordable option for most.

The bushings must be made of caprolon, it is a fairly durable polymer that is not afraid of high temperatures. The dimensions of the bushings are as follows:

• outer diameter — 11,6 mm;
• inner diameter — 5 mm;
• bushing length — 30 mm.

Need 4 bushings, and in addition, grind the cap to the following sizes:

• outer — 11,6 мм;
• inner — 5 мм;
• head — diameter 25 mm, thickness 3 mm.