Since owning this car the inlet manifold has split 3 times, im starting to get sick of it. It's the right hand side one as your facing the car from the front every time. I've only had the car 23 months. I did get the car remapped and I'm wondering if that has anything to do with it. It was a celtic tuning remap.

Going to cost another 1k now to fix again

Well more boost would strain it.

Or maybe use higher quality part?
Or don’t use full throttle

Its a good garage that did the work and they did say they would use genuine as for rpm I was in cruise control doing 75ish on the motorway.

Celtic maps are known to be "not very good"

Remove the map and fit a genuine manifold

If you do want it mapped again afterwards, stick to a specialist tuner (Alive/BAS etc)

I'm removing the map definitely. I only had it done to help towing the horse trailer, we no longer have horses so not thatch need for it.

Why did you need to map it to tow horses? My SDV6 pulls our horse trailer very nicely. 2012 SDV6 - it's missing a couple of cylinders
2008 TDV8 - it was a labour of love and is much missed

Just wanted more torque and a few more mpg, it went from 22 with the trailer on up to 26.5

Just heard from the garage and they said the egr is stuck and that's what's caused it, is this possible? I'm trying to figure out how that would work

Was the EGR ‘soft deleted’ i.e. coded out of action by software as part of the map?

Hot exhaust gasses melt plastic manifold
If stuck open

I'm not sure I will phone the garage this morning and ask them. But if it was coded out for the map, surely it would stay closed and not recirc the hot gasses. I couldn't see any evidence of melted plastic on the manifold but I guess if it got very hot a few times it could of become more brittle

Let's hope that whoever does the job doesn't have to replace it within 9mths.

This was one we did last year. First it split along the seam while the owner was driving down the motorway and went in to RP. He called the AA out and they insisted on doing a road side repair (at the services) using 2 part epoxy glue. That fix worked until it cracked across the top

Click image to enlarge

One of mine cracked a couple or three years ago. Got the RP warning if trying to drive too enthusiastically. Had both replaced - much of the labour is for stripping / replacing the stuff around the manifold so doing both worked out cheaper than doing one then the other 6 months later.

So far, so good. Now on 132k miles. 2012 SDV6 - it's missing a couple of cylinders
2008 TDV8 - it was a labour of love and is much missed

Car is ready,
Replaced the manifold yet again
Remapped back to standard
Replaced 1 x egr valve

£900 cash

Was expecting a much bigger bill

 Barrie.
2017-Jan 2024: 2005 RRS 2.7TDV6. Best car I ever had - until now!
Current: 2018 Ford Ranger Wildtrak 3.2