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Old 16-01-2008   #1
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anyone removed the intake manifold?

just wondered how easy it is to remove on a jtd? im wanting to clean it out before the rr day. i know the egr can be a pain but i would put a new one on at the same time.
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Last edited by stilosporting; 16-01-2008 at 11:01.
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Old 17-01-2008   #2
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Re: anyone removed the intake manifold?

Hi mate,

I have removed the intake manifold on JTD's before. Its not too bad, but you have to remove lots to get at the bolts (including the EGR) which but the way, i have found the easiest way to remove it is:
1. Remove the pipe between the EGR and the inlet manifold
2. Remove the 3 bolts securing the EGR to the manifold,
3. Down where the overboost valve is (if you havent moved it) there is a 10mm bolt securing the pipe that runs from the EGR down to the Exhaust manifold. Undo this. This will allow you to push the EGR backwards, making it much easier to get at the 2 allen bolts that are underneath the EGR valve securing the pipe from the exhaust manifold to the EGR valve. (the ones that are a real pain to remove with it in position)
Disconnect the multiplug from the EGR and your done!

Another issue to be aware of when removing the manifold from the JTD is that there are some cooling pipes that run across the top of the manifold and they are welded to it. You need to remember to disconnect the rubber pipes at either end.

Also whilst you have it off, I would consider changing the glow plugs if they are getting old, as they too can be a git to do with everything in the way.

But on the cleaning out front, mine had a 1cm thick layer of crud all the way around the inside of the manifold!! Had to soak it in petrol and thinners for a whole day and spend a ling time with a brush but got it all out eventually, and noticed a gain in performance and MPG when it was all back together.

Hope that helps,
Alan
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Old 17-01-2008   #3
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Re: anyone removed the intake manifold?

thats very helpful cheers.

dont think i will need to change the glow plugs. the car is an 05 plate with 52k on the clock? would you recommend changing the gaskets too? will the cooling pipes piss out coolant when i disconnect them?
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Old 17-01-2008   #4
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Re: anyone removed the intake manifold?

Hi mate,

You should be ok with the coolant, as iirc its only return pipes. I would change the gaskets, they're pretty cheap even from fiat. Glow plugs will prob be ok to.

Alan
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Old 18-01-2008   #5
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Re: anyone removed the intake manifold?

anyone got an eper image of how to remove the intake manifold cause i want to clean the injectors and their buried underneath and looks like quite a task to get to them.
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Old 18-01-2008   #6
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Cool Re: anyone removed the intake manifold?

Quote Originally Posted by Stilatos View Post
anyone got an eper image of how to remove the intake manifold cause i want to clean the injectors and their buried underneath and looks like quite a task to get to them.
3 hour job all told and thats why I got my injector fitted by a garage and didnt do it myself I have two new injectors spare for the 1.6 if anyone wants to make me an offer

And one eper image as reqested

http://eper.fiatforum.com/eper/navi?...=3&WINDOW_ID=1
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Last edited by PNL; 18-01-2008 at 16:17.
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Old 21-01-2008   #7
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Re: anyone removed the intake manifold?

not to sound ungrateful but the link just shows me a blank screen? any chance of uploading it up here ?
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Old 22-01-2008   #8
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Re: anyone removed the intake manifold?

i got it guess link was down before. thx
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Old 27-01-2008   #9
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Re: anyone removed the intake manifold?

it there a better way to clean the manifold like using some sort of Intake Cleaner spray? can i use those Carb Spray cleaner for diesel engine?
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Old 27-01-2008   #10
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Re: anyone removed the intake manifold?

it depends how gunked up the intake is. You dont want it to go into ur engine.
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Old 01-02-2008   #11
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Re: anyone removed the intake manifold?

so the idea of using cleaner to disolve those build-up and let is burn out in the engine is not good?
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Old 01-02-2008   #12
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Re: anyone removed the intake manifold?

NO; bad idea

If you're that bothered about it then take it off (can always polish it too )
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Old 01-02-2008   #13
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Re: anyone removed the intake manifold?

or get it powdercoated
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