The dealer told me there was a manufacturing fault with the crankshaft. When the crank journal was drilled for the oil to run through, they evidently started drilling in the wrong place (then correctly finished the job in the right place) and this ripped out the bearing cap. Sounds like a load of sh!t to me as the engine has never been pulled down to physically make an inspection of the crankshaft.
I assume that Ford have issued a service bulletin of some sort to the dealers, to advise that vehicles with such and such a sido number may have a problem with the engine. If this is the case, it should have taken them 5 minutes to compare numbers and not the nearly five working days that it took them, to identify the problem.
The engine makes (or made) a tappity tap noise at about 2500RPM. This tapping sound was at valve speed and not engine speed and sounded exactly like a noisy tappet/lifter. I told the dealer I suspected the problem was in the valve train and was suprised to be informed (intially they said a bearing, then they come up with the faulty crank line) that they suspected the problem was in the bottom end of the motor.
I'm not ungrateful, as afterall, I'm getting a new engine at no cost to me and I've been supplied with a brand new BA until the problem is fixed. It's just that it's taken 3 weeks to get this far (not including 2 previous trips to the dealer to identify the problem - and it wasn't on either occasion) and I feel a bit like a mushroom, shovelled sh!t and kept in the dark. Oh yeh, Ford also sent (allegedly) the lower spec engine, not the VCT engine and this also held procedings up. I'm supposed to get the vehicle back today (tues). Here's hoping.
Some of the people that visit this forum would have an intimate insight into how things are done at the dealers (and Ford itself I suppose) I just wondered if what I've been told, sounds ridgy didge?