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Title: 2.3 16v Plastic inlet manifold Post by Scorpio_Mike on May 25th, 2008, 10:17pm Anyone know if the 2.3 Scorpio inlet manifold is the same as the one on the 2.3 Galaxy ? |
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Title: Re: 2.3 16v Plastic inlet manifold Post by 5stud on May 26th, 2008, 12:33am no genuine galaxy manifolds use a blanking gasket at front and have no water in them .so no leak problems..they have no enserts fore water pipe or electric sensors.the water flows front to backof head useing the blanking plate you find on backof 2.0 and 2,3 scorpios heads if you are looking for a scorpio inlet manifold i have a spair |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Scorpio_Mike on May 26th, 2008, 8:10am Thanks for the info. I saw a 2.3 Galaxy inlet manifold on ebay for £19.99 - thought it might be worth picking up as a spare. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on May 26th, 2008, 1:05pm hi there pm sent. cheers andrew |
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Title: Re: 2.3 16v Plastic inlet manifold Post by jonnycab on Jun 5th, 2008, 1:30am I just bought a 2.3 galaxy inlet manifold off Ebay for £15 & it is identical to the 2.3 Scorp manifold. Granted, it doesn't have the brass nut fittings for the sensors or a brass outlet pipe for the matrix hose, but the ones from my old manifold should pop out easy enough & with some new O rings.....& maybe some extra strong high temperature glue......should whack into the Galaxy manifold, no problem ;) As stated before, the Galaxy doesn't actually use the t-stat housing part of the manifold. So seeing as it has never had any use, then there shouldn't be a problem with it splitting at anytime in the near future....unlike every second hand Scorp one I've ever bought ::) P.S.....the manifold was 'buy it now' £19.99, but those nice people at Ebay gave me a £5.00 gift voucher to spend on anything over a tenner. So the manifold only cost me £14.99 ;D......alot cheaper than a used Scorp one & it has an unused, good as new t-stat housing ;) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on Jun 5th, 2008, 6:47am hi jc very interested in this news. ;) can you send me a photo or two? cheers |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Simmo on Jun 5th, 2008, 7:16am We have the JC 'airlock removal system' can we now look forward to a 'JC manifold mod' !!. :D ;D |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Tompion on Jun 5th, 2008, 10:18am Thanks for the info JC, I nearly bought that one. Expect the prices will go up now. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by jonnycab on Jun 5th, 2008, 5:31pm It also doesn't have the fittings for the t-stat cover bolts, but again, I'll have to rip 'em out the old manifold & fix them in :) I wonder if Ford sell the sensor fittings etc on their own ? :-/ |
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Title: Re: 2.3 16v Plastic inlet manifold Post by jonnycab on Jun 5th, 2008, 6:04pm A blank canvas at the moment :)....... http://i70.photobucket.com/albums/i101/jonnycab/4-1.jpg http://i70.photobucket.com/albums/i101/jonnycab/P5260048.jpg http://i70.photobucket.com/albums/i101/jonnycab/1-1.jpg |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on Jun 5th, 2008, 6:32pm eyes off any more!!! they're mine! ;) ;D |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 8th, 2008, 4:44pm Done ;).....the 2.3 Galaxy manifold is now a 2.3 Scorp manifold :D......... http://i70.photobucket.com/albums/i101/jonnycab/P5290048.jpg It was a b*****d getting the fittings out of the old manifold. I ended up cutting the t-stat housing to bits with a hacksaw ::) I couldn't get new O rings so I just left the old ones in place & smeared slow setting, extra strong high temp glue around the fittings & pressed them in with a G clamp & a piece of wood, so as not to damage the housing. The t-stat cover fittings had to be filed down slightly as they were never going to go in without running the risk of cracking something. So once filed down a tad, I used the glue & G clamp to fix them in, but the one in front of the temp guage sender had to be hammered in very carefully as I couldn't get the G clamp in there. Managed to get it most of the way in with only about half a mm protruding, then filed it flush with the face :) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on Jun 8th, 2008, 4:57pm hi there good work jc. i'm winning a bid on ebay at the moment for one, so fingers crossed. andrew |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on Jun 8th, 2008, 5:45pm won it!!!! :) jc, you don't have any spare 'inserts'? or if anyone else has a broken 2.3 manifold. :) that way i could give it to my 'gas man' completed. not sure how he'd feel about doing the mod. :-/ |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Simmo on Jun 8th, 2008, 6:01pm Jon, That looks a top class job :). Mike |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 8th, 2008, 6:09pm Sorry Andrew, no spare inserts I'm afraid....not unless the current repaired manifold that is on the car splits open tomorrow ;) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on Jun 8th, 2008, 6:15pm hi jc Quote:
that's what i'm hoping for!! ;D i'll just print this topic out and see what he says. :-/ worst case is waiting to the end of the month. the wife's away for 10 days so i can use her (normally mine now) car. cheers |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on Jun 12th, 2008, 9:43pm hi there well my manifold arrived today. i've stripped the throttle body and egr off it and gave it a clean inside with carb cleaner. just need the inserts and i'll then take to get the gas nozzles fitted. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 13th, 2008, 2:12am Great news Andrew ;).....once the inserts are in & the manifold is fitted, then hopefully no more leaking t-stat housing for a long while.......may even outlast the car ;D If you're interested in the glue I used to fix the inserts.... It's this stuff :) (http://www.diy.com/diy/jsp/bq/nav/nav.jsp?action=detail&fh_secondid=9254536&fh_view_size=6&fh_location=%2f%2fcatalog01%2fen_GB&fh_search=glue&fh_eds=%c3%9f&fh_refview=search&ts=1213319407527&isSearch=true) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scorpio_man on Jun 13th, 2008, 8:18am hi jc yes, i've used that before, but a saw a 2 pack/1 (http://www.buckandryan.co.uk/product.php/section//sn/UNI964763) dispenser which can go to 150 oC. though about trying that. :-/ regards |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 17th, 2008, 3:31am Not sure that it really matters what glue you use, as it probably isn't needed.....the fittings are an extremely tight fit & are pretty hard to press in....but once in properly, then they obviously aren't going to come out again :) An extra bond of high temp glue will probably make 'em stick in even better than the original Ford factory fit & less chance breaking the seal & spinning the brass nuts when trying to remove a sensor ;) The fittings I removed had no evidence of glue on them, so they are obviously just pressed in at the Ford factory without any kind of adhesive :) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jun 11th, 2013, 9:02pm Know this is an old topic but currently modifying a 2.3 Galaxy Manifold to fit a 2.3 Scorpio and have a few questions: What are the 'O' rings? I've removed all the brass fittings from the old manifold to fit in new, but could see no 'O' rings.....do they fit around all the brass fittings? What glue was used by you guys? The links sadly don't work anymore that highlighted them. Will the coolant pipe brass fitting hold OK with just glue? That's the only fitment I'm worried about getting to fit to be honest! Many Thanks in advance guys ;) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jun 12th, 2013, 10:42am Have ended up buying this glue: http://www.diy.com/nav/decor/tiles/adhesives-sealants/adhesives/-specificproducttype-specialist_adhesive/Unibond-Repair-Plastic-Power-Epoxy-25ml-12599208?skuId=13119914 but still wondering what/where these 'o' rings are as I've not seen them! Are they really required? Have got a box of different sized o rings I cold use if necessary. ??? |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Tompion on Jun 12th, 2013, 10:17pm The 2 temp sensor fittings & the coolant pipe stub have grooves turned in them that the O rings fit into. The coolant pipe stub has a fine saw tooth tapered thread. Whether or not it will cut its own thread I don’t know, some of them have slots in the flange so they can be screwed in with a C spanner. There are a lot of special loctites, I wouldn’t be surprised if one of the range was used. The 3 inserts for the stat housing would worry me most since the bolts are trying to pull them out, especially as a sudden loss of coolant on the 2.3 can result in a cracked head. It looks to me as though the originals were put in hot so the plastic melted around the knurl. If I remember correctly you could use longer bolts on 2 of them & get a nut behind the housing if you wanted. Undoing the stat cover puts a lot of stress on the housing if the bolts are corroded, fitting stainless bolts may help. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jun 13th, 2013, 1:01am Tompian, now it's making more sense....I know the 'o'o rings you mean....was thinking the thermostat housing brass fittings should have a 'O' ring hence my confusion! ;) Will place the brass fittings in with my loctite all purpose epoxy and take it from there. Will probably allow it to set then clean up the thermostat bolts and have the thermostat and housing in place before refitting the manifold. :-X Thanks for your input |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 14th, 2013, 3:26am The glue I used was called 'Serious Glue' made by Evo Stik. Not sure if it's still available though :-/ I've got a couple of old Galaxy manifolds (& a load of brass inserts) in the shed that I've been meaning to convert for a couple of years now, but never seem to have the time to do it ::) I was thinking though, that a thin smear of good old silicone clear gasket sealer would probably do the job better than any kind of glue as it's very strong, & extremely heat resistant. This old post has inspired me to get to work on converting these manifolds....so should have them for sale soon :) Scrappydoo, be careful, that Unibond stuff you bought says it's heat resistant up to 150 degrees C, but that doesn't mean it can withstand a constant heat of 150 degrees C. Also, it may not be resistant to antifreeze ;) The Evo Stik 'Serious glue' that I used was heat resistant up to 260 degrees C & although it didn't state it was resistant to antifreeze, it seemed to do the job. But five years on from this post starting, I am inclined to use silicone gasket sealer, as I said before, it's strong & very heat resistant....but more importantly, it's antifreeze proof ;) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Simmo on Jun 14th, 2013, 5:29am JC. If you do refurbish these units could you provide some photos and a write up please. :) Mike. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 16th, 2013, 1:50am Aw...do I have to ? ::)....'spose I could ;) Not much to it really though, just remove fittings from old manifold & press them into the new manifold with a G/F-clamp, with a small block of wood on the other side between clamp & manifold to prevent damage to manifold. It's not really rocket science :) Could give the whole manifold a clean as well, outside & in with carb cleaner & hose. I'm thinking I may use the dishwasher for this job though....just don't tell the wife ;D |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Simmo on Jun 16th, 2013, 7:48am on 06/16/13 at 01:50:50, Jonnycab wrote:
Now look......we've got the JC air removal info so let's have another JC gem for all time!. :D ;D.....as for telling the wife. :o ....as if......provided......... :-X Mike. UPDATE. Just got your PM. Be great to see you if you can ;) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jun 21st, 2013, 4:19pm on 06/12/13 at 22:17:31, Tompion wrote:
Couldn't find the "fine tapered thread" on the coolant pipe stub so glued the end and then fitted it and seems strong. Also glued the sensor fixings and they also seem fine but the thermostat housing bolt fixings when trying to bolt thermostat housing they started to spin. Wonder if the glue I'm using it appropriate as it only seems to semi-set i.e. the glue on the housing threads is still moist even though it's been left for days! Been looking at Jonny Cab's recommendation of "Serious Glue" from evostik but it claims 130c and not 260c as mentioned so doesn't seem on the face of it to be any "better" that the stuff I'm using, it also only comes in 5ml so would possibly need more than the one of it. ??? |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Tompion on Jun 24th, 2013, 4:19pm The thread on mine is about .5mm pitch (50tpi), the temp inserts use much the same but have to be pushed in due to them having the hexagon recessed into the plastic, the ratchet shape of the thread helping resist removal. As you can see mine has slots for a C spanner, is threaded & has a groove behind the thread for an O ring. http://i.imgur.com/QioZ94n.jpg |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jun 25th, 2013, 12:52am Tompian, thanks for the insight.....pretty sure my coolant pipe didn't have such a thread but it seems so "held" in place now don't want to remove it really to check! Just at a loss to know what to use to hold the thermostat inserts in place. :( |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 25th, 2013, 9:25am on 06/21/13 at 16:19:20, scrappydoo wrote:
Sorry, my mistake, got my centigrade & fahrenheits mixed up ::) P.S... you can get it in 33g tubes :) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jun 25th, 2013, 12:04pm on 06/25/13 at 09:25:39, Jonnycab wrote:
Don't worry, does that actually set solid? The stuff I bought doesn't hence it's not holding the threads in place for long! :o |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jun 25th, 2013, 1:27pm It does set very hard, but still has flexibility, so can still give a little under strain so as not to fracture :) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jun 25th, 2013, 7:46pm Will be getting some serious glue from HALFORDS tomorrow! SCAPPYDOO PLEASE READ THIS (http://www.fordscorpio.co.uk/cgi-bin/yabb/YaBB.pl?board=Advice;action=display;num=1143273574) Snoopy |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jul 3rd, 2013, 3:09pm Firstly, Snoopy many apologies on my faux pas! Secondly job now completed, the only thread I managed to get to stick in the end even with serious glue was the one that you can't get a bolt through. So the other two I've ended up using longer bolts with washers and a nut to hold it in place. I've gone for the start up and the bloomin' thing is running like a bag of sh*te and it seems there's a leak (hissing sound) coming from from where the EGR valve goes to the part that transfers any exhaust gas to the exhaust manifold. I know I did loosen and remove the bolts on this to make movement of the pipe where it goes to the inlet manifold easier. I did refit and tighten them though but on checking n I noticed there was no gasket...not sure if there was one or not so I re-used the gasket from the EGR blank off that was on the galaxy manifold which fitted like a dream. Started it again and still running the same...i.e. sh*te and still a bit of a hissing sound coming from it. Have scanned it but no codes found, wondering what to try next! |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Tompion on Jul 3rd, 2013, 3:40pm You could spray around the manifold with WD40 – the revs will change if you find the leak or stick a bit of tube to your ear like a stethoscope & try & detect the source of the hiss. I’d just pull off each hose in turn & put my thumb over the hole to try & find the culprit. Causes I’ve read on here include trapping a pipe under the inlet air control valve or disturbing the engine breather located behind the exhaust manifold – it’s the other end of the metal pipe that runs around the back of the engine & connects to the inlet manifold with a right angle rubber boot. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jul 3rd, 2013, 4:11pm Have tried the WD40 trick but no sucess, the hissing is definitely coming from the EGR valve area. Does the EGR valve have a gasket between the pipe going to it? |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Tompion on Jul 3rd, 2013, 5:31pm The 24v EGR is shown as having a gasket so I assume the 16v has. If you haven't disconnected it it seams strange if it's that. The engine breather (PCV) isn’t far below the EGR, have you tried plugging the engine breather stub at the inlet manifold end to rule it out. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jul 3rd, 2013, 5:35pm Tompian, I did disconnect it to enable easier movement of the EGR pipe where it enters the inlet manifold. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Tompion on Jul 3rd, 2013, 6:04pm Did it enable easier movement? as there's also a bracket at the back of the engine. Yes, gasket shown here: http://www.fordscorpio.co.uk/images/dohc23egr.gif |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jul 3rd, 2013, 6:16pm on 07/03/13 at 18:04:55, Tompion wrote:
No it didn't really make movement easier but I still managed to move the pipe enough to make removal of inlet easier. Might do a compression test tomorrow just to rule any of the cylinders out. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by TiberiuS on Jul 3rd, 2013, 11:43pm scrappydoo: It sounds very much like a vacuum leak if you've got a hiss, usually any misfire caused by a vacuum leak not bad enough to actually stall the engine starts to smooth out if you give it a bit of throttle. Otherwise, does all the wiring you disturbed look OK? Multiplugs properly seated on both coilpacks and all 4 injectors? Does the wiring around the rear of the cylinder head and near the fuel rail look OK? MAF plug seated correctly? |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Jonnycab on Jul 7th, 2013, 2:43am There is a gasket between the manifold outlet & EGR pipe, if memory serves me correct, it's red with one big hole in the middle & two smaller (bolt) holes either side (No 6 in Tompions last link). I re-used the old gasket & just spread a bit of 'Hermetite Red' gasket sealer on both sides of it & never had any vacuum leak problems :) Hope this helps :) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Sep 11th, 2013, 6:07pm A belated update and sorry for the boring length of the post! Discovered hiss to be coming from the rubber end of the breather pipe that fits into the side of the engine under the exhaust manifold. Had to remove exhaust manifold to get at it and found it off though it was split so new one ordered and fitted....before refitting I examined the exhaust manifold and found it to have a crack in it....strange as no noticable noise coming from it only noticed out of chance. Managed to find a cheap replacement and refitted everything including new gaskets for manifold to head and manifold to cat. Got car on the road and running brilliantly for last few weeks except for a rattle from the cat clamp/bracket and the temp gauge now goes from the middle to low randomly. For the exhaust rattle I don't think I've fitted the bracket proiperly but I was struggling to get the bolt that tightens the clamp/bracket to adjust properly. Anyone got any tips? For the temp gauge issue I'm thinking the sender as this was potentially affected when the inlet manfold was replaced. Just to add insult to injury when taking it for a quick spin the other day the ABVS/Traction Light came on and later the car started running like a right bag of s***e! On investigation with a scanner it came back P0340 cam sensor and C1095 ABS pump. Examined cam sensor and found the wires going to the sensor wiring plug had come adrift.....had already completed a repair to the wiring plug with some araldite but this had come astray as it was hot so have affected a temporary repair with some cable ties. As for ABS pump this is obviously the same code that comes up when the controller circuit board requires soldering but I have already done this repair earlier this year.....could it really fail again so soon after? ??? |
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Title: Re: 2.3 16v Plastic inlet manifold Post by leewar on Sep 11th, 2013, 9:35pm I in no way mean anything by this but was the repair done properly. Once re-soldered it should not only be better than the original, but last a lot longer. ;) |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Sep 11th, 2013, 9:45pm Maybe I was a bit tight with the solder the first time, will try again! Anyone got any tips on the cat clamp/bracket? I couldn't get the actual bracket/clamp to round off enough to give the actual tightening bolt enough "purchase". |
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Title: Re: 2.3 16v Plastic inlet manifold Post by Tompion on Sep 11th, 2013, 10:41pm Check the 30amp fuses to the ABS one of them will give a C1095 code. I’m only aware of one failure of the dozen or so I’ve soldered but maybe people didn’t like to say ;) In that case it was because I’d used a new small soldering iron instead of the 50yr old big one I normally use. I think for one of the pins there’s a track on both sides of the board & the heat hadn’t got through to the underside. As I’d already cut an extra hole trying to find the problem apart from using more heat I also linked a wire across: http://i.imgur.com/ex8kyTr.jpg It can be tricky getting the pins clean, I scrape off the clear mastic from the surrounding area with something like a matchstick then I gently close a pin vice onto the pins & revolve it to clean off the old solder until I’m back to clean brass then use something like alcohol to clean the area. I always inspect the solder joints with an eyeglass & redo them if there’s a blowhole or black deposit in the solder – I suspect when this happens it’s some of the clear mastic has remained & contaminated the solder. |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Sep 15th, 2013, 11:31am The light hasn't come on again now for 3 days so I'm going to monitor it. Still got the exhaust clamp/bracket rattling against the cat mind you! |
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Title: Re: 2.3 16v Plastic inlet manifold Post by scrappydoo on Jan 6th, 2014, 2:18pm Unfortunately the small pipe next to the thermostat housing came off on the M40 last night and has caused the engine to overheat and seize! :( Looks like it's going to the scrapyard in the sky sadly :'( |
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