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Thread: 1.8vvt Insignia AirBox Front Support Bracket Broken away from Alloy Casting. + Pics

  1. #1
    Regular Member 67688c's Avatar
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    Default 1.8vvt Insignia AirBox Front Support Bracket Broken away from Alloy Casting. + Pics

    I gave my car a good clean today in preparation for starting off on Holiday 6am in the morning. When I checked under the bonnet to top up washer bottle, and give a quick wipe round in there I noticed that a chunk of the airbox bracket which holds the front Airbox mount grommet has completely sheered off.
    Its a allow di-casting and part of the upper left engine mounting casting, so the whole of the top engine mount will have to be replaced.
    The piece that had broken off was lying in the plastic tray thingy under the engine.

    So now, I've got nothing supporting the airbox at the front, and I'm about to set off on my hols for a week. Not very good at all! Geeez... I have never had a new car with so many teething problems.

    TBH I honestly cannot see how its got broken, other than someone hitting it with a hammer or something. I find it hard to believe the vibration or stresses from holding the airbox in place would have done this. So now there's nothing to hold the airbox mount grommet in place.

    I did have some resonance noise issue's which had been coming from the airbox, and these were profesionally fixed by the Hereford Vx dealer, by putting some pieces of foam underneath it.
    I'm 99% sure the support bracket was intact on Thursday, and the car went into the dealer on friday (yesterday) morning for the exhaust catching the body, and for a sticking starter motor which made a whining noise when first starting after standing overnight, although they said they had fixed it, its exactly the same. Now the day after I spot this broken away.

    The car was actually booked in to have a Tank Vent Valve Solenoid replaced, but it had not come into stock, so why they booked it in is beyond me when they had not even got the part. The other 2 minor issues were mentioned by me while I was there.
    Hmmmmm... my suspicious nature is giving me all sorts of nasty thoughts.

    Not good at all. Now I've got to wait a week until I get back before it gets ordered, and god knows how long thats going to take, in the mean time there's barely anything holding the airbox in place. There's only 2 supports anyway, now its down to just one.
    Does'nt seem to be any way I can get a cable tie around it either.
    Last edited by 67688c; 11th July 2009 at 19:22.

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    Not the best of luck. Having looked at mine and though I've got a 2.0 TDI. I would be surprised if it was more than a faulty cast or damaged prior to fitting to the car.

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    Regular Member John C S's Avatar
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    Maybe the stealer broke it???????

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    Unable to look at pictures any idea why? Its says no Permission

    steve
    Last edited by stephen160; 12th July 2009 at 16:27. Reason: error

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    Regular Member Tadpole's Avatar
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    That's not good at all I would have my doubts as to being metal fatigue. Not knowing how it’s fitted I would suspect over tightening on a big scale or it was damaged prior to fitting.

    Hope the holiday goes well Cameron despite this ………………

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    Without taking the air box off my motor, it looks like its fited over the suspension mount

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    Quote Originally Posted by stephen160 View Post
    Unable to look at pictures any idea why? Its says no Permission

    steve

    Probably need to get your post count up bud.


    The fracture is clean so I'd say it's a manufacturing fault rather than a VX fault right now.

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    Regular Member 67688c's Avatar
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    Well fortunately, it did'nt give us any issue's while on holiday, we had a fantastic day at Billing Aquadrome rally and it was great to meet a few of the members, before we travelling up to Scarborough on the Monday.
    (Not talked so much in ages...LOL) I'm the one in the Billing Pics looking around 98yrs with the big monkeys arse on his head. Looking like he's crawled out of his coffin to attend the event.

    There is only 2 mounts holding the Insignia 1.8vvt airbox in place, the one nearest the bulkhead is just a large grommet which goes into a slot, so can move about. Its this front one that stops it moving around too much.
    There is'nt really any stress placed on it, as it only has the weight of the airbox which is quite light, so I've no idea why it fractured other than it must have been already cracked or something when fitted. I've not heard of any others fracturing, so is probably just a one off.

    They are fitting a complete engine mount assembly on Monday so hopefully that's it for a while.

    Fuel consumption seems to be improving a little now the car has got 2100 miles on it. Currently showing 34.6 mpg which is not too bad for the weight of the car.
    Last edited by 67688c; 18th July 2009 at 12:38.

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