Yello
Got myself together today and decided to have a go at inlet manifold and EGR. EGR part is not completed as of now, no time today. But I spent like 3-4hrs cleaning the inlet manifold. And I tell ya, it looked horrible. I started with getting off the engine cover (obviously). Then removed the air filter box to make some more room, it is hold by two bolts. I also replaced the air filter as I had one purchased some time ago. Once Air box was removed I could easily undo two nuts and one bolt that hold the parts B(inlet manifold), C (butterfly valve housing) and D(pressure sensor housing) together. See pic.
These are quite easy to separate. I also removed the pipe that is connected to inlet manifold, two nuts on each end. It is marked as the A on first photo. It wasnt to bad.
It took some time to properly clean all parts. I didnt use anything on actual manifold, just cleaned it with a cloth. To clean part C and D I used stuff from halfords, gunk I think it is called.
Some pics - before and after:
Part B - inlet manifold
Before:
After:
Part C - Butterfly valve - it is mirracle it worked, take a look
Before:
After:
Pard D - Pressure sensor. It was absolutely covered in black oily stuff, how it managed to work I dont know. Spent half an hour to clean it properly.
Before:
After:
To do all this you need standard set of sockets and a ratchet, I think 12mm and 10mm, plus screwdriver and few bits. Used a few cloths, the amount of black stuff was incredible, sticky thing was pretty hard to remove. As you can see from pics it looked terrible. I also lost one nut and a small bolt...went down to bottom engine cover I can hear it rattling but cant find the blooming things. Part E on first pic is a butterfly valve mechanism, you dont need to do anything to it. Dont forget to plug everything in, plenty of wires and hoses. Oh And I also cleaned hoses, bit of a oily stuff in there. Once everything was in place I started my car and...it worked to my very big relief. Got to drive it for a few miles now see if its ok.
Will try to do second part tomorrow (wife/weather permitting), that will be the EGR valve. I would highly recommend doing this to all diesels owners specially ones that own a car that have 100k on clock like mine. Once I clean the EGR I am going to use the BG244 stuff, should come tomorrow.
Hope it will help someone, dan
Got myself together today and decided to have a go at inlet manifold and EGR. EGR part is not completed as of now, no time today. But I spent like 3-4hrs cleaning the inlet manifold. And I tell ya, it looked horrible. I started with getting off the engine cover (obviously). Then removed the air filter box to make some more room, it is hold by two bolts. I also replaced the air filter as I had one purchased some time ago. Once Air box was removed I could easily undo two nuts and one bolt that hold the parts B(inlet manifold), C (butterfly valve housing) and D(pressure sensor housing) together. See pic.
These are quite easy to separate. I also removed the pipe that is connected to inlet manifold, two nuts on each end. It is marked as the A on first photo. It wasnt to bad.
It took some time to properly clean all parts. I didnt use anything on actual manifold, just cleaned it with a cloth. To clean part C and D I used stuff from halfords, gunk I think it is called.
Some pics - before and after:
Part B - inlet manifold
Before:
After:
Part C - Butterfly valve - it is mirracle it worked, take a look
Before:
After:
Pard D - Pressure sensor. It was absolutely covered in black oily stuff, how it managed to work I dont know. Spent half an hour to clean it properly.
Before:
After:
To do all this you need standard set of sockets and a ratchet, I think 12mm and 10mm, plus screwdriver and few bits. Used a few cloths, the amount of black stuff was incredible, sticky thing was pretty hard to remove. As you can see from pics it looked terrible. I also lost one nut and a small bolt...went down to bottom engine cover I can hear it rattling but cant find the blooming things. Part E on first pic is a butterfly valve mechanism, you dont need to do anything to it. Dont forget to plug everything in, plenty of wires and hoses. Oh And I also cleaned hoses, bit of a oily stuff in there. Once everything was in place I started my car and...it worked to my very big relief. Got to drive it for a few miles now see if its ok.
Will try to do second part tomorrow (wife/weather permitting), that will be the EGR valve. I would highly recommend doing this to all diesels owners specially ones that own a car that have 100k on clock like mine. Once I clean the EGR I am going to use the BG244 stuff, should come tomorrow.
Hope it will help someone, dan