Maniflod and air Intake cleaning

[Awnish]

Hello every body

Iam planing to DIY manifold and air intakes manual cleaning because my car is suffering of self ignition before spark and knocking.( with a service word appear in the board dash with a limited performance)
Pointing here that my engine is 1.2 i thp 130 (eb2dts) and my car is peugeot 308 t9 2016.

Could any one help me if there are videos and step by step procedure with the materials and tools that should I use and any advice while doing that.

Also what is your opinion about oil catch can , dose it eliminate all the problem that mentioned above ?

Thanks

[MattBLancs]

I've cleaned out the inlet manifold and head of a DV6 (1.6 HDi diesel engine) I've also cleaned up the inlet manifold of a DW10 (2.0 HDi diesel)

Diesel engines, with EGR and oil in the intake airstream (from PCV and slightly from turbo) are notorious for building up deposits in the intake.

If inlet manifold on your engine is (easy to remove and) aluminium, then so long as any sensors etc can be removed then I highly recommend fire to remove most of the built up muck. I used a blowlamp and electric heat gun to pump heat and air into the inlet. Do this intensely for a short while and the muck catches light and burns off. Keep up the heat gun fresh air supply and only a thin spot layer remained. This is how I cleaned up the DW10 manifold.

The DV6 has a plastic manifold, so arson isn't the answer. Foaming oven cleaner is quite good and cutting into the muck in this scenario. Also recommend old tooth brushes to scrub gently. Head gun can be used again - this time on the plastic shaft of an old tooth brushes to allow you to reshape it and so clean round corners is possible! Mild solvents, white spirit, etc. All help to loosen the muck.
In short it's an awful messy job

Note oven cleaner= caustic= not "safe" for contact with the aluminium. Eats into it a little, gives off (chlorine??) gas and generally not recommended.

Matt

[MattBLancs]

Cleaned with fire!

[MattBLancs]

DV6 intake tract, pre cleaning. Deposits very solid, ended up scraping with a rounded flat screwdriver to get the thickest bits moving

Matt

[Awnish]

Can I use carbs spray that melt the carbon ?

[MattBLancs]

Can I use carbs spray that melt the carbon ?

Yes think should be ok. Would check compatibility with plastic (if plastic manifold) - have a read of the tin before attacking the manifold.

If cleaning out the inlet ports the suggest a piece of wire poked down each inlet - confirm valves on that cylinder are closed. Then ideally use compressed air to blast the dislodged muck out. Note it goes everywhere doing this so mind your eyes! Then turn engine (spanner on crank pulley bolt) and close next cylinder's valves before cleaning the next inlet tract.

I'd suggest white spirit as good product, nice and cheap. Carb cleaner ok but might need a few tins - not sure how bad (direct injection?) Petrols get, but you can get a feel for the scale of the job on my pictures of the HDi inlets.

Matt

[Rhothgar]

I've cleaned out the inlet manifold and head of a DV6 (1.6 HDi diesel engine) I've also cleaned up the inlet manifold of a DW10 (2.0 HDi diesel)

Diesel engines, with EGR and oil in the intake airstream (from PCV and slightly from turbo) are notorious for building up deposits in the intake.

If inlet manifold on your engine is (easy to remove and) aluminium, then so long as any sensors etc can be removed then I highly recommend fire to remove most of the built up muck. I used a blowlamp and electric heat gun to pump heat and air into the inlet. Do this intensely for a short while and the muck catches light and burns off. Keep up the heat gun fresh air supply and only a thin spot layer remained. This is how I cleaned up the DW10 manifold.

The DV6 has a plastic manifold, so arson isn't the answer. Foaming oven cleaner is quite good and cutting into the muck in this scenario. Also recommend old tooth brushes to scrub gently. Head gun can be used again - this time on the plastic shaft of an old tooth brushes to allow you to reshape it and so clean round corners is possible! Mild solvents, white spirit, etc. All help to loosen the muck.
In short it's an awful messy job

Note oven cleaner= caustic= not "safe" for contact with the aluminium. Eats into it a little, gives off (chlorine??) gas and generally not recommended.

Matt

I reckon I am going to be giving this a shot tomorrow.

Any tips on getting the inlet manifold off on DW10? The diagrams that Citroen show for mine are in fact incorrect as my EGR lies horizontal and the UFO with vacuum to diaphragm points upwards and is visible from the offside wheel arch.

My mate has a battery operated buzz gun for getting into tight places so I am hoping it's really easy. Cannot get the vacuum pump gasket without a 10 day wait from Citroen so will take some cereal packet just in case I need to make a gasket.

He has a compressor so I guess I just need my blowtorch to get the fire raging.

Another friend has walnut blasting kit but that seems a right faff. Easily than taking the head off I suppose.

Why did you specifically do this job of removing the gunk?

Also where is the PCV valve on an HDi please?

I am doing it as I believe that my MAF sensor readings and intermittent turbo pressure issue is due to a serious build up of gunk.

I am using Car Scanner with an ELM327 and it is reporting 13-15 g/sec airflow at idle. A typical figure should be 2 - 7 g/sec. Lexia reports 450mg/cp but I've no idea what the conversion is unless it is

450mg/cp (basically 0.45g) x 820 rpm x no of cylinders (cp?) / a random 100? which would work out at 14.76g/sec???

On full throttle, it sometimes throws a pressure fault and indicates the turbo is only giving 1700mbar (0.7 bar above atmospheric) as opposed to 2000mbar (1 bar above atmospheric).

Be really interested to hear your reasoning and the outcome.

[MattBLancs]

[

I reckon I am going to be giving this a shot tomorrow.

Any tips on getting the inlet manifold off on DW10? The diagrams that Citroen show for mine are in fact incorrect as my EGR lies horizontal and the UFO with vacuum to diaphragm points upwards and is visible from the offside wheel arch.

My mate has a battery operated buzz gun for getting into tight places so I am hoping it's really easy. Cannot get the vacuum pump gasket without a 10 day wait from Citroen so will take some cereal packet just in case I need to make a gasket.

He has a compressor so I guess I just need my blowtorch to get the fire raging.

Another friend has walnut blasting kit but that seems a right faff. Easily than taking the head off I suppose.

Why did you specifically do this job of removing the gunk?

Also where is the PCV valve on an HDi please?

Be really interested to hear your reasoning and the outcome.

Ah, unfortunately I only have half a story for the 2.0 HDI - the manifold I cleaned was one I've bought separately. I've cleaned it ready to fit (but the car in question needs a load of welding and it's probably years before I will touch it) I bought a complete manifold as it came from a 110 bhp van so would allow fitting of an intercooler (to my 90 bhp, non-intercooled 306) and also as it was cheap (£20 delivered) and I thought I could clean up and sell my current manifold for pretty much no cost.


I've read inlet manifold removal is a nightmare on the 2.0 HDi given the engines angle and it's all on the rear side. Hope you post back soon to say it was a walk in the park!

Will try and look for the PCV valve today and put a picture up if possible

[Rhothgar]

OK. Thanks. Didn't do it yesterday as put back out on Thursday. It feels a lot easier now but not sure I should go up to my mate's and wiggle about in the cold.

Am looking into the weird AC setup on Xantia instead. Cannot believe the fans come in when slider is set to demist. That means I've been driving around getting poor MPG because engine doesn't warm up as quick as it should. Will do a separate post about this though.

Citroen neighbour says undo top engine mount and rotate engine forward to make it easier.

[MattBLancs]

Am looking into the weird AC setup on Xantia instead. Cannot believe the fans come in when slider is set to demist. That means I've been driving around getting poor MPG because engine doesn't warm up as quick as it should. Will do a separate post about this though.

Citroen neighbour says undo top engine mount and rotate engine forward to make it easier.

Demist activates air con, air con activates radiator cooling fan(s) - yep that's normal.

However, radiator having the fans running should make no bearing on warm up times - as the thermostat should be shut and the coolant in the engine block is recirculating (only to the heater matrix basically)

Might be worth sticking a new thermostat in or take current one out and test in pan of water heater gently on the stove


Yes top mount removed will allow it to rotate, jack and piece I'd wood under sump to take the weight. Please bear in mind it's very keen on rotating back more (IE towards the bulkhead!) under its own weight, so hinders as well as helps!

[Rhothgar]

I've read inlet manifold removal is a nightmare on the 2.0 HDi given the engines angle and it's all on the rear side. Hope you post back soon to say it was a walk in the park!

Will try and look for the PCV valve today and put a picture up if possible

Such a walk in the park because I still haven't done this job...

By the time, I get around to it, the gasket I bought will be creased and bent in half in the boot of the car.

[MattBLancs]

I've read inlet manifold removal is a nightmare on the 2.0 HDi given the engines angle and it's all on the rear side. Hope you post back soon to say it was a walk in the park!

Will try and look for the PCV valve today and put a picture up if possible

Such a walk in the park because I still haven't done this job...

By the time, I get around to it, the gasket I bought will be creased and bent in half in the boot of the car.

Ha ha! Life gets busy, nevermind! I've still not provided the promised picture of the PCV valve either! Was that in the DW10 (i.e. a picture of my 306's engine bay) ? Is it still of use?


I find the best way of keeping gaskets in good order is keeping them well away from...

...me!

[Rhothgar]

I don't honestly know about the PCV valve. It probably would be useful. What I find strange also is the orientation of the EGR. On mine it is vertical yet in the official manual it is horizontal on some engines. The studs on mine look REALLY ropey. I daren't try and remove EGR. It's working so I'll leave it but think because it is vertical it does need to come off to get the manifold off!!!

PCV photo would be useful as I was unaware they had one. No rush. Anytime in the next 12 months should be fine.

[MattBLancs]

PCV photo would be useful as I was unaware they had one. No rush. Anytime in the next 12 months should be fine.

Oh that's the sort of arduous deadline I can work with!


Will try and get at the EGR valve too just for interest.


The DW12 EGR valve in my 406 Coupe is surprisingly accessible.

The other good news on that engine is that it's not on studs, instead the manifold has clearance holes and big standard hex head M6 bolts thread up through the manifold into tapped holes in the EGR valve body. So if they were to shear it's only extraction from EGR valve (which can then be done off car) to contend with, rather than facing removing the manifold itself.

Not sure if all EGR are like that, in fairness minimal interaction with EGR systems thus far for me!

[MattBLancs]

PCV photo would be useful as I was unaware they had one. No rush. Anytime in the next 12 months should be fine.

Oh that's the sort of arduous deadline I can work with!


Will try and get at the EGR valve too just for interest.

Still not done this, have I!?