NHTSA Complaint #10354915 — 2002 FORD ESCAPE

WHILE STARTING THE ENGINE AFTER OVERNIGHT PARKING, A LOUD EXPLOSION WAS HEARD AND WHITE SMOKE WAS SEEN COMING FROM UNDER THE HOOD. THE IGNITION WAS IMMEDIATELY TURNED OFF. EXAMINATION OF THE ENGINE REVEALED A DAMAGED DECORATIVE COVER OVER THE INTAKE MANIFOLD AND SHATTERED INTAKE MANIFOLDS. TWO SPARK COILS WERE LATER FOUND TO BE DAMAGED BY THE EXPLOSION. THE HEADS WERE RECONDITIONED AS IGNITION LEAKAGE THRU THE UNSEATED VALVES WAS A FACTOR CONTRIBUTING TO THE IGNITION OF THE RESIDUAL GASES IN THE INTAKE MANIFOLD. SECONDARY CONTRIBUTION WAS THE ORIGINAL INTAKE MANIFOLD WAS OF AN OLD STYLE AND NOT CAPABLE OF WITHSTANDING THE BACKFIRE FORCE. A NEW, MODIFIED COMPOSITE INTAKE MANIFOLD WAS AVAILABLE BUT NOT ON A RECALL. *TR