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Ford Kuga 1.6 Ecoboost 180:bhp Titanium X - Broken Spark Plug Destroys Engine - Speedbird 747

Very low mileage car for year.

The engine started making a knocking sound after a long run. No warning lights, engine didn’t seem to be running rough apart from the knocking. Sounded like camshaft. Pulled over immediately and switched off engine. Did not drive it again

RAC engineer suspected camshaft. Car relayed back to a main Ford dealer from where the car was purchased 18 months ago with a Ford Warranty Protect Gold insurance policy. That was the 12th December.

Dealership could not find a fault with the camshaft or hub bearings. Rod knock then suspected. However one spark plug had apparently broken (Ford made) and dropped into the cylinder. Boroscope showed the rings,,cylinder and piston damaged. Cylinder head too. But hard to believe all this damage was caused with no warning at all. Not even fault codes indicated this.

Insurance has refused to pay for a new engine. Apparently even with a brand new car after it is only a year old, a spark plug that damages the engine is not even covered by the manufacturers warranty. First I have ever heard that it is possible for a £2.50 component like a spark plug, to cause over £8,000 worth of damage.

Edited by Speedbird 747 on 31/01/2022 at 20:46

Ford Kuga 1.6 Ecoboost 180:bhp Titanium X - Broken Spark Plug Destroys Engine - craig-pd130

Sorry to hear that. It's relatively rare for a spark plug's ceramic core to fail and fall into the cylinder but it does happen, and will cause the damage you report. Peugeot's 1.2 3-cylinder turbo motor is apparently prone to similar plug failure and engine damage.

Is the car actually out of the warranty period? If it still has warranty remaining I would play merry hell with them, a spark plug is a service item but NOT a 'wear and tear' item like a clutch, brake pads or tyres. The plug should last between scheduled services, and assuming that you have stuck to the recommended service intervals then I would think you have grounds to fight to get this covered, at least in part.

Ford Kuga 1.6 Ecoboost 180:bhp Titanium X - Broken Spark Plug Destroys Engine - elekie&a/c doctor

Spark plugs on these have service life of around 80k miles on these engines. Any signs of overheating or coolant loss? It's possible the spark plug failure is the result of another underlying problem.

Ford Kuga 1.6 Ecoboost 180:bhp Titanium X - Broken Spark Plug Destroys Engine - Speedbird 747

Many thanks for your comments.

Still hoping to turn this around. But in this day and age, spark plugs should be redesigned if it is possible for them to wreck engines.

The spark plugs were in good condition and not due to be replaced at last service. The argument is whether a spark plug is a consumable or component, which apparently invalidates the warranty.

Ford Kuga 1.6 Ecoboost 180:bhp Titanium X - Broken Spark Plug Destroys Engine - Andrew-T

The spark plugs were in good condition and not due to be replaced at last service. The argument is whether a spark plug is a consumable or component, which apparently invalidates the warranty.

That is an argument Boris might be proud of. Spark plugs do not get 'consumed' - at least they should not, in the way yours has.

Ford Kuga 1.6 Ecoboost 180:bhp Titanium X - Broken Spark Plug Destroys Engine - John F

The spark plugs were in good condition and not due to be replaced at last service. The argument is whether a spark plug is a consumable or component, which apparently invalidates the warranty.

That is an argument Boris might be proud of. Spark plugs do not get 'consumed' - at least they should not, in the way yours has.

It is a disingenuous and fallacious argument attempting to introduce a false distinction. A spark plug is of course both a component of a petrol engine and a consumable, in as much as it needs to be replaced as per the service schedule, timed to be well before it either performs badly or wears out.