2.4 jtd throttle body
Decided to clean out the intercooler and associated hoses as had good results on my previous car, a Volvo V70 T5. I removed the top hose from the intercooler and the bottom hose which goes to the outlet on the turbo. Then I used some rag to block the bottom of the intercooler and simply poured Mr Muscle into it until it filled it. I then left it for a few moments, drained it and then cleared it through with hot water until it ran clear.
I then refitted the hoses and started the car until a let it tickover until I was sure most of the water was out of the intercooler.
I then removed the hose again from the top of the intercooler and to the 'throttle body' part of the inlet manifold. It was absolutely filthy and clogged with oil from the breather and other muck. I decided to clear it out and noticed a flap in there. Judging by the angle the air enters the manifold and has to pass over the flap, it seemed more of a hindrance, so I temporarily removed it and cleaned it out. Whilst it was apart, I used a flap wheel to smooth the sides of the piping and cleaned out the egr.
I also noticed that someone had blocked off the egr which I decided to leave.
Once put back together it ran a lot smoother, but I still get the engine light on around 3,500 - 4,000 rpm. MAF changed since, VNT module stripped & reassembled and also the pipes to the VNT changed to silicone . May yet change them to rubber as I think the silicone is not rigid enough.
Unsure when to fit the butterfly flap back.