Excessively 'clogged' inlet manifold (pics) - Alfa Romeo Forum
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(Post Link) post #1 of 12 Old 13-02-10 Thread Starter
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Excessively 'clogged' inlet manifold (pics)

Hi,
I decided to clean the throttle body in my car (GT 1.9JTDm) it was heavily soiled on the butterfly with tar/sutty carbon. so i fully removed it and when i peered into the inlet manifold i couldn't beleive the amount build-up of carbon on the inside...absolutely caked in it, had a little poke at it and it was really compact.

I've not attempted to clean it out as i don't know if this is normal (i can't imagine it is) and it looks like a big job cleaning it out. If its not normal build up, then has some other factor contributed to the manifold getting in such a state?...ive popped a pic on to see inside.
any suggestions and advise would be great.

Cheers Mark
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take it to local engine builder and ask him to drop it in his hot tank , clean it up nicely
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(Post Link) post #3 of 12 Old 14-02-10 Thread Starter
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is that kind of build up normal on the inside? its done 80k
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is that kind of build up normal on the inside? its done 80k
Thats what you normally get with a jtd that has an operating EGR and also does a lot of short journeys.
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The way we used to clean out the exhausts on 2 strokes was to make up a solution of sodium hydroxide (caustic soda) and pour that into the exhaust and leave it for a while. HOWEVER, do not use anywhere near anything made of aluminium as there will be a displacement reaction and the aluminium will disappear.

Have you tried ordinary carb cleaner?
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would some '10k cleaner' help flush it out or is it a total removal, clean, refit? will it benifit from a clean? cheers
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Makes the JTS's suddenly look a lot cleaner!
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Quote:
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would some '10k cleaner' help flush it out or is it a total removal, clean, refit? will it benefit from a clean? cheers
I think cleaning it in situ would be a very bad idea. That is a lot of cr4p to through the engine and turbo on its way out!!

If you leave it as it is, it is only going to get worse.
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I have some carb cleaner you can try on it mate, if that fails try davealfa's suggestion? Oh and you can help check mine out too whilst at it
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(Post Link) post #10 of 12 Old 16-02-10 Thread Starter
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Had a full day of cleaning and tinkering on yellow boy (the alfa) tuesday...roped mr cave senior into giving me a hand cleaning the manifold up... Removed the egr valve, opened it up and it was packed tight with carbon deposits, it can't of been working for months! This prob links to the engine management warning light coming on intermitently about a year ago. Had a diognosis done on it back then and the code was some general electric/wiring number which didn't really point to anything...anyway cleaned egr, got valve moving freely. After what seemed an age removing and unclipping hoses and wiring looms i finally got to the manifold...cleaned it up nicely (not as bad as the pictures looked, only 2-5mm of build-up) using carb cleaner, scraper. Got the hoover out to remove any loose dust in the housing
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(Post Link) post #11 of 12 Old 16-02-10 Thread Starter
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Put him all back together, key in ignition, battery dead ... Jumped him ran it for 10 mins to get upto temp, finished off with a can of 10k boost restore in the intake hose after the intercooler...job done.instant Improvement on smoothness of revs, pull and general feel. Well worth it
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Good effort, no sign of MCSF light on yet? I wonder if you should do an ecu reset now to start a fresh? Imagine my egr is the same, though it still pulls like a train no problem
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