Manifold Cleaning

[Mirez]

Well after cleaning up the EGR system I noticed a large build up of crap within the intake manifold - obviously this couldn't be cleaned in situ so I removed it last weekend and cleaned it all out. I havn't bothered to post this as I wanted to see if there was any effect on the car or if it was a pointless exercise.

 

Well the results are in:

 

An increase in MPG over the weeks mileage from 42.9 to 50.4

Vast improvement in throttle response

Vast improvement in acceleration

Noticeable decrease in idle noise

 

 

I'll do a full write up on this later, but here are some of the pictures so you can guage the scale of the problem. Take into account that mines an 03 with just 70K on the clock...

 

Intake Manifold's err Intake:

 

A small scrape out shows thickness of crud buildup:

 

Manifolds outlet ports:

 

Crud from manifold, just midway into process!

 

Manifold's Intake after acid bath (Same as Pic1)

 

Outlet Ports after bath

[daddyfixit]

so what would be in at 146k miles ????

[seatkid]

Wow Mirez! Well done! Must say your enthusiasm for hard work is admirable. I doubt I would want to undertake a job on like that, but I look forward to the write up.

 

A couple of questions:

 

1. What fuel do you generally use?

 

2. Do you use any additives?

 

3. What oil do you use and how often is it changed?

 

The reason I ask is I wonder if using the right fuel/oil/additive combination reduces (or eliminate) this EGR build up.

 

I'm fairly convinced that using Millers power sport 4 additive must have cleaned up my EGR somewhat. At one point the old girl was wheezing and whistling terribly prompting me to start using the Millers additive. After a week of heavy dosing and several italian tuneups and lots of smoke, the whistling (and smoke)disappeared. Another definite benefit was the car now passes the MOT emission test each year on first go (Fast Pass) with extremely low numbers whereas previously it would take the full 3 passes and be pretty near the limit.

 

Over the last 2-3 months I've stopped using the Millers mailny due to laziness and also the stupid design of the container it comes in (always get it all over my hands), and I have noticed a small gradual decline in mpg and increase in idle noise, which by your observations may be the EGR getting clogged again.

[Mirez]

 

1. What fuel do you generally use?

 

2. Do you use any additives?

 

3. What oil do you use and how often is it changed?

 

 

Cheers mate, to answer your questions I use:

 

1) Total - I subscibe to the theory that supermarket fuel is generally crap and since Total is just down the road it's the easy option

2) Every now and then. I've used Millers (on your advice actually) and also some trade cleaners

3) "zgb115qlb00462" which is 5/40 every 6K. Yes I know that's way below the requirement but I get the oil at cost :)

 

I bought second hand though so the first 40K of its life it could have had anything in it!

 

I would say millers or any other cleaner should have a good effect on cleaning the injectors, cylinders and exhaust manifold but I can't imagine it will have much effect on the intake manifold, the only time its going to get up there is through the EGR system and only after its been combusted. It took a ferric chloride acid bath to disolve some of it and carb cleaner did very little!

[seatkid]

Well based on your regime, I would say that my theories are probably of no value.

 

Hopefully my old fashioned AHU tractor is not as fussy as these new fangled PD units.

[Mirez]

I'm now looking at a ProVent200 system which would hopefully stop this from happening again, seems the better option as I dont want to disable the EGR system so removing the oil vapour is the only other option.

[ggobin]

Hi. Was it easy to remove the valve and manifold ? How long did it take you? I know mine could do with a clean

 

Thanks

Gary

[Mirez]

The process is easy, the job is a little tricky as for most of it you are working blind. I'll write up a how-to for it as its certainly worth doing - the cost was just

[ggobin]

Thanks Mirez - that would be greatly appreciated. :)

[Bigjeeze]

The process is easy, the job is a little tricky as for most of it you are working blind. I'll write up a how-to for it as its certainly worth doing - the cost was just

[Mirez]

Well done Mirez - could please include in your write up any special tools etc ? This is the kind of job you need to be properly prepared for. Also - you mention using a ferric chloride bath to clean the manifold - Where do you get that from? Is it expensive or difficult to obtain - also is it toxic?

 

Yes I'll put all the required tools in the write-up but there aren't many fortunately :)

 

Ferric Chloride is an etchant most commonly used in the creation of circuit boards, you can pick it up from a number of places including maplins and ebay and its about

[Mirez]

http://www.mirez.co.uk/Galaxy/PDF/Galaxy%20-%20Intake%20Manifold%20Cleaning.pdf

 

 

Galaxy - Intake Manifold Cleaning.pdf

[ggobin]

Great doc and thank you.

[seatkid]

Very very impressive Mirez!

 

However, I'd probably buy a new car rather than tackle a job like that!

[Mirez]

Very very impressive Mirez!

 

However, I'd probably buy a new car rather than tackle a job like that!

 

It really isn't that tricky, but it is time consuming!

 

For anyone that's interested the Mann+Hummel ProVent200 is now installed :42:

Not exactly the smallest thing in the world to squeeze under the Galaxy bonnet but its in and working - guess only time will tell just how effective it is but the USA boys have been running these on VW PD engines for a good number of years with fantastic results:

 

 

Provent200:

 

Told you it was friggin massive:

 

Where it connects:

 

Pipework:

 

Cover re-attached:

[chrispb123456]

So how much is this filter Mark is it available in the UK

[Mirez]

I'm not sure you want to know!

 

There's no easy way to say it....£110 :42:

 

Oh and yes, there are a few UK companies that can supply it.

Edited July 10, 2011 by Mirez

[chrispb123456]

You'll have to strip it all down in a couple of years and see if there's an improvement :42: hopefully newer engines will have a similar set up as standard.

[Mirez]

There are many other advantages my man :42:

 

Lower intake temperature

Higher oxygen concentration so increased power

Increased response

Reduced oil consumption

Higher MPG

Reduced emisions (and subsequently hopefully just the one thrashing at MoT time)

Reduced turbo lag

Reduced turbo strain

Reduced condensation/water intake

 

I'm planning to keep this gal for a fair few years to come so the outlays worth it, plus its interesting ;)

 

As the emission directives get stricter this is more then likely to become standard.

 

I'll post up two power graphs later to show before and after power and also report back in 5k or so with the before and after opacity test results if you'd like :)

[chrispb123456]

Totally agree with your other points Mark, was just suggesting reviewing the manifold/EGR for visual inspection for any further build up of sooty deposits.

[Keithb]

For those without the skills of Mirez, I've just had mine cleaned by a local friendly mechanic for

[Mirez]

You're very welcome -

[bigdave982]

Well go on then Mirez !!! do tell

 

Trying to summon up the courage to at least do my EGR valve

[Mirez]

Ok well total distance covered is now 3,911 miles:

 

The actual fuel consumption has increased by 4mpg with an average over that distance of 47.2Mpg (Although the computer is showing 49.7 so one of us is wrong lol) however even 4mpg is a good sustained increase.

 

Now the two written tests, Having access to a tuners workshop at the weekends is a big help :)

 

There are the recorded figures:

 

As of Saturday 7th May:

Max Power: 117Bhp

Max Torque: 292nM

Smoke Test: 1.77m-1

 

As of Saturday 23rd July:

Max Power: 129Bhp

Max Torque: 307nM

Smoke Test: 0.94m-1

 

 

So I'm still missing a horse but that's an increase (recrease?) of 13 horses, which is why if feels so much keener and presumably the extra torque is the reason for the increase in MPG. The biggest change would be that smoke test though, 1.50m-1 being the MoT test limit so anything under that is an instant "fast pass".

I have a feeling there is heat absorption going on from the cheep-o pipework that I used over the crankcase so I've ordered some silicon hose and stainless pipe and I'll see if I can't route it a little better to avoid that and maybe get my horse back lol

 

I'm also toying with chipping it again, 160 is a modest increase I'm told on the 130 and since oil temperature failed to climb above 100 she would appear to be operating well within limits at the moment.

[bigdave982]

Hi Mirez, you posted a while back with regard to cleaning your EGR valve that consumption had gone back up to high 40s just form doing the egr valve

Are your new gains in addition to this or as a combined effort ,ie egr valve and manifold?

Or does doing the manifold give a better overall response th the effort

It certainly seems well worth the effort tho,if only I could find the time to do mine

Edited August 5, 2011 by bigdave982