Intake manifold cleaning.

[bigfellayork]

Sons Astra Sri diesel turbo oil seal blown.
The whole intake side is absolutely blathered in carbon oil sludge. EGR valve was blocked solid into manifold. How it even started I’m amazed.
Pipes have all been degreaser. EGR valve cleaned and throttle body delicately cleaned.
The intake manifold is caked with this thick oily carbon sludge.
Don’t want to remove it as it means cam belt off diesel pump off to get to bolts.
Anyone any suggestions for cleaning it in situ.
Cheers

 

[Ashley Burton]

Sons Astra Sri diesel turbo oil seal blown.
The whole intake side is absolutely blathered in carbon oil sludge. EGR valve was blocked solid into manifold. How it even started I’m amazed.
Pipes have all been degreaser. EGR valve cleaned and throttle body delicately cleaned.
The intake manifold is caked with this thick oily carbon sludge.
Don’t want to remove it as it means cam belt off diesel pump off to get to bolts.
Anyone any suggestions for cleaning it in situ.
Cheers

You can use intake cleaner, But it's a couple of sprays at a time. Otherwise the engine could run off.

 

[zzr1200]

Take the manifold off the engine and dump it in a bucket of celly thinners for a soak, then steam clean it, resoak and steam again.

It's too dangerous for the engine to spray cleaner into it with or without it running...

 

[thinfourth]

Not saying this is a good idea

But its an idea

Fill the manifold up to the top with kerosene or petrol and let it soak.

Then pull glow plugs and turn it over slowly to empty the bores.

Then change the oil and filter to remove any gunk that has passed the rings

 

[Dcal]

If it's proper clogged there is no real way to clean it on the engine.
There are onengine cleaning systems, see -

for one, but don't expect spraying a tin of cleaner down the air cleaner will do it and the only way the carbon can get out with a system like that is through the engine!
The ERG valve recirculates exhaust gas to the inlet, to reduce combustion temperatures and so reduce the formation NOx.
If you are doing short runs it is probably solid with carbon.
If you do decide to take the manifold off, soak the whole thing in neat TFR (traffic film remover) then pressure wash it and it will come up spotless.

 

[bigfellayork]

Cheers for replies folks. Few ideas to consider there.

 

[dobbslc]

If its the 1.9 16v CDTI engine the thick sludge was probably already there! take the manifold off and clean it. Then get the swirl flap blanking kit off ebay and fit that, they will break at some point anyway!
If you have to take the timing belt off get a new kit WITH water pump as they seize and take out the entire engine when the belt snaps!
If your sons car is pre DPF first praise the Lord then blank off the EGR valve and get it remapped asap.
If it has a DPF the EGR valve will be knackered anyway even before the seal blew so get a new one, they don't last long anyway.
It's a nasty catch 22 with these engines, once something goes out of sync it all goes to ****!
Vauxhall did an extremely bad job with the engine management / emission controls on these!

 

[Wallace]

I thought the 1.9CDTI 16v was a Fiat engine?

 

[Brad93]

I thought the 1.9CDTI 16v was a Fiat engine?

Well that would explain everything haha

 

[dab4318]

I thought the 1.9CDTI 16v was a Fiat engine?

That is correct. Just got the inlet changed on my van. Absolute pig of a job and not for your average home mechanic I'm afraid.

 

[Dcal]

Haven't done one on an Astra, but if they are anything like on a Bravo they aren't that easy.
Cam belt and injection pump needs to come off and strip the complete ERG system off, including the water to exhaust gas intercooler (the black plastic thing that sits above gearbox) and the thermostat and hoses..
It a lot of stripping but required to give you access.
The better half has one of these and that's the biggest job I had to do on it in 150k. If I'd changed the ERG valve when I should I don't think I would have had any bother.
Done nothing else on the engine except servicing and it's on the original turbo and had had just one Erg valve in that time

 

[Wallace]

That is correct. Just got the inlet changed on my van. Absolute pig of a job and not for your average home mechanic I'm afraid.

Working up to doing our Vectra, keep putting it off and finding other things to do!

 

[dobbslc]

The swirl flaps went on ours along with lots of EML lights flashing and power loss. Did 3 EGR valve's a gearbox, alternator, and lots more I've blocked from my memory!!!
Had enough and part ex'ed it for something Japanese.

 

[Migmac]

Nobody round about you doing Terra clean?

 

[octo0072000]

turbo seals blowing can be caused by blocked DPF

 

[Matrixx]

some use oven cleaner (in situ), there's a few clips on the net

 

[tinker jim]

only way to clean it with out debris going in the bores I guess is to take it off

 

[slim_boy_fat]

Take it off and put it in the dishwasher......

 

[dobbslc]

This is the state of my EGR valve manifold after about a year since it was last cleaned. You can't get any further into the inlet manifold in situ. Imagine what it's like inside!
If you've also got a load of oil blasted into it I'd say you have to take it apart.
Li

 

[Kayos]

Working up to doing our Vectra, keep putting it off and finding other things to do!

I did a Vectra C, ended up replacing loads of other stuff too. Hateful job