Yet More EGR & Inlet Manifold Questions!

[Stampie]

Hi Guys

After reading the many posts on here about the EGR problems I decided to have a look at mine today as well as trying to find the source of a black oily type of gunge over everthing under the Inlet Manifold.
The van is a 2003 2.0 Di, with 107,000 miles on it. It had no service history when I got it so i have been going through jobs one at a time to bring the van back to a good standard.

Here is what i found.....

After removing the Inlet Manifold I found this










And the Manifold itself looks like this.....






Now I'm not one to shy away from a bit of cleaning but this stuff is pretty poo! Its like a black thick sludge that is caked on everything.
But i did manage to find out how it got there.....

A hole in the bottom of the Inlet Manifold appears to be the problem






So I have a couple of questions please.
After seeing the amount of S**t in the manifold I think its a no brainer not to blank it off - So does it get blanked where you can see it in the bottom right hand corner of image number 4?
After the EGR is blanked should I clean up the mess and try and repair the hole myself - Or invest in a new manifold??

Thanks for looking your help is appreciated.

[coconut]

2 choices really

1- Clean the mess up and get a new manifold (not cheap though) as im pretty sure thats where the dipstick tube support bolts on (did you take a 10mm bolt and bracket off from there )

2 - Clean everything and patch the hole up

[Stampie]

Thanks Coconut.

No dipstick support - but on closer inspection looks like the fixing for that has snapped off the manifold too

Found brand new manifolds on fleabay for £50 - I'm guessing this is an ok price compared to what might be paid at a breakers or new from the dealer?

Plus it'll save me cleaning the crap outta the old one

[alzee20]

sounds like a good price man, im sure people said they were about £200 from dealers a while back!

[b1jc]

Done the EGR blanking over the weekend.

If you do decide to clean the manifold I found carb cleaner just kills all that hard soot.

Don't take my advice as gospel though, but I used 3 cans and seems okay.

[winterheating]

youll have to make sure the inlet manifold is identical as theres a few different ones, like some enter the otherside like a 75ps, or some have supports in for the resonator box on top, and some dont, so if you get the wrong one will mean resonator will not secure right or connect to pipework, and some have the dipstick bracket at outer edge of intake manifold.

must have been noisy like that was it

[coconut]

youll have to make sure the inlet manifold is identical as theres a few different ones, like some enter the otherside like a 75ps, or some have supports in for the resonator box on top, and some dont, so if you get the wrong one will mean resonator will not secure right or connect to pipework, and some have the dipstick bracket at outer edge of intake manifold.

must have been noisy like that was it

Very noisey and a loss of power I would have thought, it'll be a flying machine with the new one on

As said above, make sure its the correct one, think the 85ps and later 100ps manifolds are the same due to the egr bolting on the underside of the manifold rather than the pipework

[bdp210]

having seen your photos, its made me decide to get my manifold off and blank the dirty egr off too. only thing is my MOT and insurance is up next month so will have to sort some thing out.

do you have to get new seals for the inlet manifold too. my service is about due as well now so make sense to get it all sorted.

[ake]

Its good practice to replace any gasket or seal after disturbing it

[Stampie]

youll have to make sure the inlet manifold is identical as theres a few different ones, like some enter the otherside like a 75ps, or some have supports in for the resonator box on top, and some dont, so if you get the wrong one will mean resonator will not secure right or connect to pipework, and some have the dipstick bracket at outer edge of intake manifold.

must have been noisy like that was it

Very noisey and a loss of power I would have thought, it'll be a flying machine with the new one on

As said above, make sure its the correct one, think the 85ps and later 100ps manifolds are the same due to the egr bolting on the underside of the manifold rather than the pipework

Thanks for the comments guys.
Didn't notice the van being that noisy, but its my 1st Transit and my 1st Turbo Diesel so I don't suppose I'll actually know if it was noisy until I fit the new manifold. I actually thought it was running really well.... Be very interested to see if it actually makes any difference other than stopping the bottom of the engine gettin covered in s**t!

Coconut you mentioned the dipstick support... It turns out thats whats broken off and caused the hole!!

Anyway, new manifold is on its way from Fleabay £35 + £15 for shipping.
Identical part numbers to whats stamped on mine, looks new and comes with new gaskets by the looks of it.
http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... 3D1&_rdc=1

Just gotta get the engine cleaned up before it goes back together.. What is the square box that is caked in oil you can see that has 4 pipes going into it and is it safe to get it wet when cleaning??? (Pic No 3)


Just another quick question.
Where do I actually blank the EGR? At The point where the inlet manifold joins it on top that is already apart or at the point to the side where the rigid silver braided pipe comes out?? (Pic No 1)


(Gonna change the Glowplugs whilst is apart too, Lucky its only -4 outside!! )

[coconut]

Looks like the correct manifold, and at a real good price as well

The square box (never heard it called that before ) is the fuel injection pump and the 4 pipes are the pipes that supply the injectors, no problems with it getting wet (I always give them a good scrub in the parts washer and havent damaged one yet), just if your gonna use a pressure washer then avoid really blasting it into the top square bit as thats where the electrical bits are, rest of the pump body will be fine

Blanking the egr, I think the easiest & most common place is where that braided pipe bolts onto the egr, just make a blanking plate to fit in between the egr and pipe, just make sure you use plenty of wd40 on the 10mm nuts as they can rust and snap or as winterheating said, somewhere else I think, take the complete pipe off and blank both ends

Get all that done and it'll be good as new

[winterheating]

id be checking all boost pipes for splits and loose joints also turbo operation, as should have been really hissing out of that hole

[coconut]

id be checking all boost pipes for splits and loose joints also turbo operation, as should have been really hissing out of that hole

Thinking back, I once had one with an intercooler split open, the tinyest amount of boost noise, barely louder than normal, took me ages to find it and when I saw it I couldnt believe how i'd missed it but there just wasn't any noise

[Stampie]

There was a noise when driving and the turbo started to come in..

Sounded more like it was coming from under the dash more than the front of the engine bay tho... almost like turning the fan on!
Thought it might be normal on my van as its a FWD and the turbo is right by the bulkhead isn't it

The square box (never heard it called that before ) is the fuel injection pump and the 4 pipes are the pipes that supply the injectors, no problems with it getting wet (I always give them a good scrub in the parts washer and havent damaged one yet), just if your gonna use a pressure washer then avoid really blasting it into the top square bit as thats where the electrical bits are, rest of the pump body will be fine

I had to call it a square box cos it's soooo covered in gunk I could actually be anything
Day off on thursday so I'll get out there cleaning - no worries about water pressure mate - I can actually p*ss stronger than my jetwash

[coconut]

Yep the turbo is behind the bulkhead but thats also the easiest place for noise to transfer in through the heater ducting, so it might be quieter after