MajorCommonEngine

Ford Fairlane: Barra 4.0L inline-six plastic intake manifold cracking

Barra 4.0L inline-six plastic intake manifold cracking is a common engine fault on the Ford Fairlane on the 1998–2007 cars, and we rate it major. Putting it right costs $400 to $900 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 9 documented faults on the Ford Fairlane.

Vehicle: Ford Fairlane
Engine: 4.0L
Years: 1998–2007
Fuel: petrol
System: Engine

This page covers the Ford Fairlane as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Ford Fairlane faults9 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Intake manifold yet. We would rather show none than show a picture of a different part.

What goes wrong

The composite plastic intake manifold fitted to the Barra 4.0L I6 engine in the AU/BA/BF Fairlane is prone to cracking along the runner-to-plenum joint and at the vacuum take-off ports. This is the same failure mode documented extensively on the Falcon platform sharing the same engine. Cracks cause vacuum leaks producing lean running, rough idle, and fuel trim imbalances. Most failures occur after 120,000–200,000 km as the plastic ages and becomes brittle.

What you would notice

Rough or lumpy idle that may clear under load
Lean fault codes (P0171) and long-term fuel trim above +10%
Hissing or sucking sound from the intake area
Hesitation on light throttle from idle

How to check it

Where to look. Top of the engine on the intake side, bolted to the cylinder head

With the engine idling, spray aerosol carb cleaner along the intake manifold runners and around the vacuum take-off ports — a change in idle note indicates a vacuum leak. Visually inspect the plastic manifold for cracks, especially along the runner-to-plenum seams.

Parts involved: Intake manifold.

What it costs to put right

$400 to $900 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Has the intake manifold been inspected or replaced?”
“Any rough idle particularly when the engine is cold?”
“Has the car ever had a lean code or fuel trim fault?”

Now check the Ford Fairlane you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Ford Fairlane buyer questions

Is barra 4.0l inline-six plastic intake manifold cracking serious on a Ford Fairlane?

We rate it major and common on the Ford Fairlane. The composite plastic intake manifold fitted to the Barra 4.0L I6 engine in the AU/BA/BF Fairlane is prone to cracking along the runner-to-plenum joint and at the vacuum take-off ports. This is the same failure mode documented extensively on the Falcon platform sharing the same engine. Cracks cause vacuum leaks producing lean running, rough idle, and fuel trim imbalances. Most failures occur after 120,000–200,000 km as the plastic ages and becomes brittle.

How much does it cost to fix on a Ford Fairlane?

$400 to $900 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Ford Fairlane years are affected?

Our research records this fault on the 1998–2007 Ford Fairlane. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.