Intake Manifold Cleaning and OCC?

Get ready to catch all the coolant mess

 

Cleaning the intake manifold requires removing the throttle body, but does not require disconnecting the coolant lines from the throttle body. You can just lift off the throttle body and tie it to the inverter.

Cleaning the EGR cooler can be done without coolant spill too: before disconnecting coolant lines from the cooler, drain a couple of liters from the radiator, into a clean container. This will drop the coolant below the egr system, you won't lose a drop when you pull the hoses off the cooler. Then, when lifting off the cooler, be careful, there's a few tablespoons trapped at the lower back corner. Just lift the cooler up-and-out without tilting, then pour it out into the container with the rest of the drained coolant. When everything is reassembled, pour the drained coolant back into the reservoir. The level will be a little high, should settle to normal with a day or two driving.

 

Where is the gasket that some folks have had drop when removing the cooler? Is it possible to put a hand on it while removing the cooler to catch it?

 

Between the EGR pipe and valve there's a gasket that's an example of a good gasket: when you remove the pipe the gasket's clips hold it on the valve. At the back of the cooler, where it connects to the exhaust manifold: that's the problematic gasket.

It's functional, and if you reach under when pulling off the cooler, it's no problem. But it can catch you napping: it has no clips and it's back a ways, easy to miss and have drop.

Also, I found it a pain during reinstall: not having clips it's hard to judge when it's properly aligned. Maybe before trying to get the bolts through use a slim punch or awl first, to verify alignment.

I cleaned mine with only 70K kms, with fairly light deposits. I first used BrakeClean, with mixed results, and I'm not a big fan of of volatile hydrocarbons, if they can be avoided. What worked for me ultimately was to cork one end, mix a solution of near-saturated Oxi-Clean solution (a powdered laundry additive, fairly strong base, with maybe some sorta bio nibbler component?), with as hot as possible tap water, shoot it in, and let soak for about an hour. Then rinse thourough with hot water, and repeat.

It took about 5~6 soaks thus, and it was as-new clean. With each soak the stuff tends to bubble out of the top, with a froth of carbon grit. The drained water is also very dark. Each cleaning you should see less action, less carbon in the froth, and clearer drain water.

With heavy, near-total clogging, or for faster results, @Raytheeagle swears by pressure washer jet. I guess start at lower pressure (if possible) and slowly escalate.

 

Mendel knows what he is talking about here. Mine was in terrible shape. I started with brake cleaner then did 5-6 soaks in hot water and oxyclean then took 18 gauge wire to help get it cleared, then took it to a car wash using the high pressure sprayer. You could probably skip the wire step and go straight to the car wash

 

Mine after the car wash

 

You probably need to use a wire picker to open the ports up first if they are completely clogged. Then either the Oxi-Clean or the pressure wash method will be effective.

 

Squeaky clean.

 

Didn't see it coming. Now permanently RIP in the undercarriage frame work.

 

The gasket on the back of the egr cooler can be a bit fiddly, but a bit of tape locks it on the cooler.

Use the pressure washer and you’ll be done in no time .

Good luck and post some pics or data for others to benefit .

 

I feel like Leo DiCaprio in Inception looking inside that cooler.

 

Hey all,

So I started this morning in cleaning the EGR, intake manifold, and throttle body. I'm having a really hard time getting the hoses off. Any tips? Or does it requre just sheer strength? I was yanking on one attached to the throttle body and it wouldn't budge, I'm afraid of ripping it.

 

Also, my EGR pipe was filthy. I fear how clogged the EGR must be.

 

Which hoses?

The ones on the egr cooler are a bit fiddly, particularly the lower hose.

Not as bad as the ct200h hoses though.

Get the right angle and twist the hose with the help of a flat head screwdriver and that should help.

 

Literally all of them attached to the EGR and the throttle body. I tried to pull whatever I could and none of them budged as if they were glued on. I'll try to work them with a screwdriver tomorrow, thanks.

 

You shouldn’t need to take the throttle body ones off.

Once you have the air box off, set the throttle body to the side with the hose connected and you’re good to go.

Good luck and keep us posted .

 

Ah, I was following along with the NutsAboutBolts video. I'll try again tomorrow, thanks!

 

For hoses I like to push on the edge at the end with a large flat-blade screwdriver, while pulling. If you just pull on them it's like a chinese finger trap, just cinches down tighter. I see @NutzAboutBolts and @Ragingfit take pliers, grip them lightly and twist a bit.

For the throttle body coolant lines, no need to take them off, just lift the throttle body up and off to the side, tie to inverter.

For EGR cooler coolant lines,, drain a couple of quarts from the rad before pulling the lines off, and there'll be no spillage. Pour that coolant back into the reservoir when done.