Cleaning EGR + turbocharger - Alfa Romeo Forum
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(Post Link) post #1 of 15 Old 04-05-10 Thread Starter
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Cleaning EGR + turbocharger

Some time ago i noticed that my alfa isn't cuoresportivo anymore.
On the full throttle 2.4 reacted with big black cloud of smoke coming from the exhaust pipe.
After checking the MAF, injectors, IC and similar stuff, there is only one thig left to check, the EGR.
There it is:

Last edited by Sasha_CSC; 01-07-10 at 12:14.
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(Post Link) post #2 of 15 Old 04-05-10 Thread Starter
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One look on the throttle body:

And into the intake manifold:

I decided to clean all parts that are connected to the EGR.
Now, by cleaning the manifold i should prevent the carbon to reach the valves and cylinderhead.
So the manifold should be detached from the engine.
And there was the first problem.To detach the manifold i should first remove fuel pump, all belts, some wires and common rail....

Last edited by Sasha_CSC; 04-05-10 at 20:25.
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(Post Link) post #3 of 15 Old 04-05-10 Thread Starter
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After one day work intake manifod was separated form the rest.
There are some pics of the manifold egr and throttle body after cleaning:
Throttle body cleaned:


EGR before:


EGRT after:

Manifold during the cleaning process:

Manifold after:

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This was ideal occasion to replace the thermostat:

And one pic of the CH, before cleaning:

I forgot to take pic after the cleaning....
Tommorow I'll try to post pics of turbocharger.

Last edited by Sasha_CSC; 05-05-10 at 11:52.
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Good work so far, keep it up!
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(Post Link) post #6 of 15 Old 03-06-10 Thread Starter
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It's time to end the story!
Only thing that is left untouched till now is turbocharger.

This is the compressor manifold,and as you can see,it's glued with some kind of tar.
Probably from the oil outlet...

Conmpressor side...

VGT part...

And the turbine side...

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(Post Link) post #7 of 15 Old 03-06-10 Thread Starter
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After cleaning parts looked like this:

And the car is running different now.
Average consumption is lower, cca 10%.
And there are no more black clouds gushing from the exhaust
every time i put the pedal to the metal.
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Top marks for the effort. What mileage/km had yours done before the overhaul? I just cleaned my EGR recently and was loathed to put it back on very dirty TB and manifold but lost my bottle when it came to releasing some rather permanent looking clips from pipes.
Well done anyway.
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Quote:
Originally Posted by m-a-r-k-o View Post
Top marks for the effort. What mileage/km had yours done before the overhaul? I just cleaned my EGR recently and was loathed to put it back on very dirty TB and manifold but lost my bottle when it came to releasing some rather permanent looking clips from pipes.
Well done anyway.
I must admit, it was a little bit oddly that i had to do this kind of cleaning at 130k km.... but since the car was imported from Italy (used), i belive it has done more than that.
The main problem is to remove all parts that are in the way.
For example, to reach the manifold screws you have to take off: right engine holder, all belts, common rail, high pressure diesel pump with pipes, etc ...
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What are you using to get the parts that clean??
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Quote:
Originally Posted by fishy-steve View Post
What are you using to get the parts that clean??
Oven cleaner and steel brush with soft steel bristle...
For turbocharger parts i use tooth brush (be very, very gentle with those parts).
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how did you reseal teh turbo matting faces, are there seals that need replacing?
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Originally Posted by gazzaspider View Post
how did you reseal teh turbo matting faces, are there seals that need replacing?
There are no seals present, all you have to do is to clean matting faces.
And for cleaning, it's good to use material that does not leave any scratches.
I'm cleaning such surfaces with sponges for cleaning copper.
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i know this thread is a bit old now, but just wandering, when you removed the intake manifold did you have to replace the seal? if so where did you get it from as i am keen to get mine as clean as yours! great work btw.
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Quote:
Originally Posted by bradleyboy87 View Post
i know this thread is a bit old now, but just wandering, when you removed the intake manifold did you have to replace the seal? if so where did you get it from as i am keen to get mine as clean as yours! great work btw.
Don't worry, there is no need to replace the seal, actually seal on the manifold is made from some kind of steel.
So you can use it again!
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