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(Post Link) post #1 of 7 Old 18-03-12 Thread Starter
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Cleaning intake JTDm

Today I cleaned intake and turbo on my JTDM 150HP (turbo part in new thread)
EGR disablet in software at 50,000 miles, but before then it has built up a lot of dirt in the inlet.

Schematics intake / turbo
charge airsystem.jpg

Remove and clean Throttle body

Remove and claen Foot mount (letting exhaust from egr pass to intake)
Also clean EGR - best thing is never to use it again - just mount it and block it (best thing to have it deleted in software)

Take a look at intake (" *nal probing " with an iphone...)
Intake MAP.jpg

Remove MAP sensor and soak intake in intake cleaner - let it work for 1 hour

Made a blockoff plate for EGR (just to be sure exhaust never return to my intake)
Kind of bizare isn't it - connecting exhaust to intake...

Assemble the whole thing again and crossed my fingers that the car starts ...
It did not

It was drowned in the intake cleaner

After 5 attempts got it started - a lot of smoke out of exhaust
Drove a long trip with a lot of rpm.

Everything ok! it starts better and does not vibrate when it starts as before cleaning the intake.

Last edited by Viking; 18-03-12 at 21:22.
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Hi, great photos. Could you let us know how you took the inlet manifold off. Is it the same procedure as the Vectra, having to take the fuel pump pulley off.

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(Post Link) post #3 of 7 Old 18-03-12 Thread Starter
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I did not take the manifold off. think it's to big a job (for me)
Cars running fine now.
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Good one mate! Thanx for sharing. I'm gonna do the same thing these days. My 159 vibrates a bit and doesn't start emediatelly (have to keep the button pressed for 2 sec).
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Read the instructions carefully on your intake cleaner. Most intake cleaners for use on a diesel engine recommend that the intake is removed from the car before use. If you use too much there is a risk that the liquid is sucked into the bore in such quantities (it doesn't take a lot) and the engine can hydra-lock.

There are cleaners that you can spray into the engine with it running but by far the best method is to remove the intake or have the full BG service that can be done with professional equipment with the car running.
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It was mine which hydrolocked recently.
It's no problem though, either wait a while and some valve leakage will let the pressure escape, or just unscrew the glowplugs and crank the engine over a few times to empty the cylinders.
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i havnt had my EGR deleted from the software, if i just block it off, i know it will bring up check engine light.
will this cause any problems to the running of the car???
if not, i may just block it up and get deleted from the software when i have some spare cash...
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