Manifold and EGR Changed After Cleaning
 

After sourcing a couple of diesel manifolds and cleaned them also couple of EGR's i decided to change them ready for the summer months ahead i know seems i have jumped the gun :roll: as its's now snowing :gmc: anyways some of the photo's below of how i am changing the manifold and EGR.
Fig 1 the components Arhh yes also the engine cover
http://i43.tinypic.com/35mik4n.jpg1

EGR valve fig 2
http://i44.tinypic.com/a1pf7d.jpg

Cleaned out manifold fig 3/4
http://i41.tinypic.com/ok0isg.jpg

http://i42.tinypic.com/255j9sg.jpg4

Engine cover removel three bolts fig 5/6
http://i43.tinypic.com/9jp2qa.jpg5

marked with yellow dots
http://i52.tinypic.com/4j6nwx.jpg6

Next remove the air duct five bolts fig 7/8/9
http://i42.tinypic.com/aw87i8.jpg7

marked with green dots
http://i51.tinypic.com/1zgfhiu.jpg8

removed and ready to be set aside safely
http://i43.tinypic.com/be6dfc.jpg9

manifold and EGR exposed fig 10
http://i40.tinypic.com/156fsj9.jpg

Unclip the fuel line fig 11/12
http://i43.tinypic.com/rvw004.jpg11

http://i43.tinypic.com/24wsq6p.jpg12

remove vacum pipe from EGR fig 13
http://i39.tinypic.com/33jjwd1.jpg13

release EGR pipe clip fig 14
http://i41.tinypic.com/11r7zv8.jpg14

Snow stops work in progress fig 15
http://i40.tinypic.com/2ibeqki.jpg15
To be continued :cry:

Resumed 5/2/12

Remove the hose from the EGR fig 16
http://i43.tinypic.com/24uyn2b.jpg16

release the cam sensor wiring gromit from manifold fig 17
http://i43.tinypic.com/jj48zq.jpg17

Unplug the MAP sensor wire from the manifold opposite side fig 18
http://i44.tinypic.com/8yumtj.jpg18

The manifold is now ready to be removed by undoing the eight bolts at the top and the five at the bottom fig 19
http://i42.tinypic.com/23t4407.jpg19

Once all the bolts and nuts loose/removed lift mainfold free along with the attached EGR fig 20/21 ready for the cleaned one to be fitted if you have one if not you will need to clean your own along with the EGR if cleaning your own do it on a nice warm day as this could take an hour or so.
http://i43.tinypic.com/123m690.jpg20

http://i40.tinypic.com/308cj61.jpg21

As i already had a replacement manifold and EGR cleaned and ready to fit it was just a case of removeing the dirty EGR fig 22
http://i40.tinypic.com/2bqw4z.jpg22

Cleaned one and dirty one side by side this one is not that bad have seen some really crudy ones well blocked. fig 23
http://i39.tinypic.com/a0z3th.jpg23

Next remove the MAP sensor 10mm bolt as the can get cruded up as well and will need cleaning with some carb cleaner fig 24/25
http://i39.tinypic.com/opbqxt.jpg24

http://i44.tinypic.com/6oz7tg.jpg25

MAP sensor removed note the black sticky goo on the end this can sometime be really crudy and hard give it a spray to soften do not chip or scrape at the sensor once softened wipe clean with a rag also wet with carb cleaner then wipe dry.fig 26/27
http://i43.tinypic.com/169rnmf.jpg26

http://i44.tinypic.com/14bpcld.jpg27

Once cleaned fit the MAP sensor back along with the cleaned EGR to the manifold ready to be fitted back to the engine make sure all the rubber gaskets are in tact and in place properly fig 28/29
http://i40.tinypic.com/4v5qtv.jpg28

http://i40.tinypic.com/2uq2jyu.jpg29

Fit the manifold back in place along with all the other items ie hose to EGR vacum little hose, MAP sensor wire,fuel pipe hose, cam sensor wire gromit etc double check everything is in place.fig 30
http://i40.tinypic.com/156fsj9.jpg30

Replace air intake pipe fig 31
http://i44.tinypic.com/b46yb8.jpg31

Then finaly fit the engine cover all this helps the engine to breath a bit better and can help with MPG fig 32
http://i39.tinypic.com/255otv8.jpg32

If you have a turbo sensor like i do this also can be cleaned at the same time with carb cleaner remove the small hose which connects between the EGR and the turbo sensor fig 33
http://i44.tinypic.com/142rfgh.jpg33

Unplug the wiring to the sensor fig 34
http://i44.tinypic.com/i2v8gl.jpg34

Remover the other hose which connects to the intercooler and remove the sensor housing fig 35
http://i40.tinypic.com/15gp4ic.jpg35

Fig 36 the sensor inside the housing which can be sprayed with carb cleaner mine was quite clean really but still sprayed it once shaken dry reverse fit job done.
http://i40.tinypic.com/20ql5bk.jpg36

I also replaced the fuel filter at the same time which you may wish to do also you can find the how to for this on another thread hope this helps some members Arctic.

nice one Steve

thats a good write up i have a spare inlet manifold for mine and a spare egr valve thats like new after helen went out and i put it throu the dishwasher to cleen the egr.

whats the best way to do the bypass using a old egr i noticed its alloy so cant weld it shut lol


oh also not forgoten to get helens tourer coulor code just cant be botherd to look at plate yet

Not done the EGR bypass myself but am led to believe you just pinch the little vacum pipe closed and refit the hose :shrug: sure someone will correct me if i am wrong

Yet another excellent article :D

Been copied to here as usual ;):bowdown::D

When do you it, look at the disgusting mess that comes out - it's all thanks to your EGR.

Get it bypassed!

to block my EGR off i used a 2p coin and removed vacuum pipe and put a self tapper in the end

thats a idear then i took and blocked the vacume of it in theroy the egr with out the vacume should be gass tight but after all these years i recon it will leak some

Seems some pics are missing from the thread Arctic

There are various methods, in order of easiness...

1. If the small vacuum pipe is simply prevented from applying any vacuum, that will prevent the EGR valve from opening. Disconnect it and block the end of the pipe, or block and refit, or simply close up the stub pipe on the EGR and refit. It will not help if the exhaust valve is passing though.

AND/OR
2. Seal the stub where the exhaust fits onto the EGR.

3. Fit a modified EGR or a complete EGR bypass.

Any of the above will prevent any further build up of the horrible black gunge in the EGR and the inlet system.

EGR Bypass ??
 

This is something that I am considering doing on my 75 cdt, I would really appreciate any advice as to whether this is a " good" mod and what damage bypassing the EGR may cause?

All advice welcome!!!!

With respect to the manifold, assuming it was caked up beforehand (?) have you had the clean one on long enough to notice any difference in performance or mpg?

Hi,
I cleaned my maniflold & egr about 6 months ago & found the car runs a lot smoother & about a 3 mpg improvement.

Cheers Mel.

What method is best for cleaning the manifold? Have heard all sorts such as putting it through the dishwasher, using a bottle brush and petrol and others.

Which method do people find works best?

Chris

Hi Chris

I just used a engine degreaser sprayed it and let it soak over a few days mind i could afford too as i had a couple i bought spare.

this was my last spray the day before i fitted the manifold i then power washed it out with a jet washer ;)
http://i41.tinypic.com/ok0isg.jpg

ready for fitting
http://i42.tinypic.com/255j9sg.jpg

all is in link below.

https://www.the75andztclub.co.uk/forum/showthread.php?p=927819#post927819

Hi artic
Brilliant write up,just one question did you reuse the manifold gaskets.

Yes checked them all and in good condition as are rubber i used the ones which cam with the spare ones i bought and have yet to clean my own which i took off. ;)

An excellent write up Arctic, a quick question, how tight are the bolts and any danger of rubber gaskets falling into engine when removing the manifold.

Worth doing, if you want to avoid the need to clean the EGR and inlet. Bad point is that there will be slightly more emission at low revs. The fitting of EGR's was an attempt to reduce the emmissionsas they come from the factory, but likely after a few thousand miles and due to the caked on muck, the emissions will be made worse.

The difference is not detectable during the MOT test.

Bolts were not really tight if you are asking me how tight in specified torque its M6 bolts 10Nm -lbf ft 7 M7 nuts and bolt 15Nm lbf ft 11 i use rule of nip up till tight then a third turn i tightend them from left to right every other one so as to keep them even or criss cross which ever you feel best with. someone may jump on board and give you how they tighten theirs there are nine bolts and four nuts i doubt the rubber gaskets will fall into the engine all mine stayed in the inlet manifold. Arctic

Need to clean my inlet manifold.Have soaked it in white spirit.Would it be ok to power wash it? nothing internal that might get damaged.Great thread & pics Artic!

As long as you remove the MAP sensor and dry it properly, should be fine.

Thanks Jakg

And if your worried about removing the inlet manifold, another how-to in addition to Arctic's

http://www.the75andztclub.co.uk/foru...d.php?t=102098I should of said that I tried using a hose but it was nowhere near powerful enough to blast out all the ****, and my car hasn't exploded since.

As Above remove the MAP clean that with carb cleaner quick burst dont soak it, then jet wash Manifold through every single hole even the little one where the MAP sensor fits if you do not have a jet cleaner at home see if you can get to a jet wash at a garage and use that some have hot jet washes even better. :xmas-smiley-029:
http://i49.tinypic.com/sevq5h.jpg

http://i46.tinypic.com/1zly9nk.jpg

http://i46.tinypic.com/30cnerl.jpg

There is really only one proper way to clean the inlet manifold as far as I am concerned.

I paid a local engineering company £20.

They sprayed the inside with a high pressure heated mix of kerosene and steam.

The inside is literally how it came from the factory. Shiney and looks brand new. Not a speck of black crud anywhere.

However, it actually made no difference at all !!

Worth getting this done by someone else with the proper stuff. The stuff inside will be seriously carciogenic/toxic, not to mention the mess it makes. Just not worth the hassle.

The EGR on the other hand....... ! Well worth doing.

I am sure it must have made a difference i know how i would like my manifold to be inside, don't forget some of the manifolds can be really bad which in turn make the engine bore close up as below this was a members manifold i changed for them :icon_eek:

Well thats the thing I thought about...

On a turbo engine, it will pressurise the manifold to a set pressure.

Should the airflow be slightly restricted, all thats going to happen is that the air will flow faster through the manifold, but the same volume of air will still be getting through surely?

Unless of course is so badly restricted there is backpressure to the turbo....

Well thats how I was thinking anyway...

Not sure on the exact physics principles!!

Diesel Manifold Gunk (what's yours like ) ?
 

I cleaned out four manifolds this weekend starting on a Friday by removing the EGR, MAP sensors, and rubber seals.

Then scrapped out as much gunk as i could from each manifold, then it was sprayed with oven cleaner and engine degreaser they ere then left over night ready to finish cleaning out on the Saturday.

There must lots of owners running around with clogged up manifolds stopping the engine from breathing proper.

All have differing amounts of gunk in them some that just trickles out when scrapped off the internal ports,https://i.imgur.com/1dtpmdVl.jpg1

https://i.imgur.com/HihBM3tl.jpg2

https://i.imgur.com/vAVeawPl.jpg3

https://i.imgur.com/bR56QN0l.jpg4

https://i.imgur.com/DL5pSLSl.jpg5

A lot of owners add bypass EGR thinking that will help, but in fact all it is doing is hiding the trouble in the manifold that as already occurred, and needs dealing with for the engine to breath properly.

https://i.imgur.com/ZrfYzQ9l.jpg6

https://i.imgur.com/3fYhXull.jpg7

https://i.imgur.com/y13A7eql.jpg8

It took me 5 hours to scrape out all the gunk from these manifolds, even then there is still quite a bit that is hard to reach which the oven cleaner and engine degreaser soaking over night will loosen, ready for the jet washing of the manifolds.

Some of the tools i use and always wear thick rubber gloves this muck get everywhere, it will ruin your clothes if you get it on them.
https://i.imgur.com/RLoXR27l.jpg9

https://i.imgur.com/qZMBiuBl.jpg10

Jet washing took place though out Saturday which took another 5-6hrs.

https://i.imgur.com/aqyAGqKl.jpg11

https://i.imgur.com/Mk69cnul.jpg12

https://i.imgur.com/3C8LKj7l.jpg13

Ready to have the clean EGR and MAP sensors fitted, some will have an original gutted EGR others just the EGR not touched.
https://i.imgur.com/vYgmG1Nl.jpg14

https://i.imgur.com/GIbbGPil.jpg15

First one sorted ready to befitted on a local car at the Nano in Oct 3rd
https://i.imgur.com/snQ4u83l.jpg16

All four re-built and also ready for the meet.
https://i.imgur.com/6i18qgkl.jpg17

https://i.imgur.com/MQWkpLOl.jpg18

I must say i was pleased with the out come ;)
https://i.imgur.com/WAhPfU8l.jpg19

If you are going to the Nano meet and would like a swap out of your manifold EGR, MAP sensor then drop me a PM Arctic.