Have you considered that it was the MAF sensor screen that got into the blower's impeller since you don't recall removing it?

 

His MAF is in the stock location (on the blow through side).

 

Like SC/TA said, the MAF is on the blow thru side. I finally got the blower off and it doesn't look good, but not as bad as I thought. Plus with further inspection/cleaning of the intercooler piping, I have found the majority of the shavings. I am going to drain the oil tomorrow and check it for any shavings and hopefully that will give me a better idea how much got into the engine. If there is shavings in the oil then the engine is pretty much toast.

 

I would be more concerned about what the cylinder heads, valves, cylinders and pistons look like than the oil. Not sure what the worry is with the condition of the oil...what "shavings" would you be likely to find??? The s/c is self-contained and all the mystry parts appear to have gone into the intake.

 

Although most of the time it is recommended that the MAF is placed between the s/c and the intake, the "stock" location (if there is such a thing on a blower car), is on the suction side of the s/c. Driveability/tuning seems to be better when located on the pressure side. Just an FYI.

 

When I said "stock" I meant before the S/C was put on the car. I was just letting you know the MAF was on the pressure side of the S/C. Yes, I agree the drivability is better on the pressure side.

 

Most of the time on high lift cam cars the pieces bounce around the cylinder a couple of times and get spit out in the exhaust. On cars like my ford focus (small valves and low lift) that dropped a valve seat it will bounce around in the cylinder and destroy the head and piston then moves via the intake manifold to the other cylinders. You can hear it if it is in the cylinder. It sounds like marbles getting bounced around in a can.

 

Sorry for your bad luck Steve. Although better to have it happen to your Ford than your Pontiac. Was this a warrany issue or a known problem with that particular Ford 4 cylinder? (Not intending to hyjack the thread, just curious)

 

Yep pretty common. I got the car for cheap so no big deal. I just put a reman from Pep Boys in that has a 3yr 100,000 warranty.

 

no way for metal to get to the oil from the intake really, wouldnt hurt doing oil change anyway. If it sounds normal and runs normal then everything should be just fine. I would check out the piping and intercooler for remaning metal chunks.. they might come loose one day.

For proof, I would take out all the plugs and check with one of those bore scopes things... flexible camera jobs, look around in the cylinders see if you see any metal flakes or scratches on pistons. If you dont have any signs of metal flakes or piston scratches then absolutely nothing to worry about. Everything likely came in the intake valve and blew out the exhaust.. and the fact that you drove it along time since the problem happend then any potential damage is likely done and gone. Aluminum is soft and cant really get pushed by iron rings and cyl since they are so hard.

Aluminim is pretty soft however it could get stuck to your valve seats and create loss of compression but it would get better as it cleaned up.

I sucked in a bunch of dirt and gravel in a 4cyl S-10, then I heard a piece of rock must have been stuck to the piston cause it was banging for about 5 miles then all the sudden it went away.. I figured it came lose and blew out the exhaust port. That happend at 100,000 miles and motor ran to 200K+