3.2 DiD Inlet manifold cleaning

redvers · Fri Jul 13, 2012 7:22 pm

Hi All

Started to do a major service and block the egr off. Air, oil, diesel filters, diff oils, brake fluid and antifreeze. heater t pieces, oil pressure sensor and thermostat.

After seeing how much gunk there was here, i decided to remove the inlet manifold and clean this. Finding out that this is not an easy task to tackle. stripping and stripping more and more as you go along to get the inlet manifold off.

Just spoke to Marius and he said that I still need to remove the injector pipes from the pump as well. More stripping and I think this will be the most difficult part.

here are some pics so far

: inlet manifold

: throttle body

: body cover

: egr inlet

: egr valve

: turbo

I have noticed that this wiring plug does not connect to anything. Is this correct or is there something missing

: wiring

Also what is missing here. It appears as if there was a connection simmilar to the one next to it here. What does this do?

: what is this

Now I hope the knowledgeable gents will advise and help

Thanks to Marius so far.

4ePikanini · Fri Jul 13, 2012 7:39 pm

Yours doesn't look too bad but worth the clean.

After speaking to you i remembered some more bad news. I had to remove the tappet cover to get the pipes that go into the head back on the injectors...... You may be lucky and may not need to do this. Do that part first when reassembling and then connect to the pump.

To clean the intake spray with brake cleaner, leave it for a few minutes, hose off with pressure washer. Repeat until satisfied.... An old toothbrush helps.

That connector at the boost sensor is disconnected at mine as well. Dont know what its for.

You need to get that vacuum nipple sorted. Its either the cut off diaphragm solenoid or the idle solenoid. Look here

https://www.pajeroclub.co.za/forum/viewtopic.php?t=3035

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redvers · Fri Jul 13, 2012 8:03 pm

Hi Marius

is the item circled in yellow the vacumn nipple. I see that there are 2 off these on this unit. i there take it there should be 3 then. I dont have any problems with idle of killing the engine

thanks and more stripping

What is the procedure to bleed the injectors again after assembly

4ePikanini · Fri Jul 13, 2012 8:29 pm

Did you check my thread i posted to understand that system and cross checked with yours?

No bleeding needed. Just prime the filter pump and crank for a few seconds.

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andrew.ashton · Fri Jul 13, 2012 8:53 pm

hi @redvers / Marius,

This inlet strip and clean is on my list for a week or two down the line - I also want to do the top chain guide and and replace the chain ratchet mechanism at the same time and do EGR delete. I hate to think what my inlet looks like at 225k km.

Any chance that one of you could post a list of the gaskets / non-reusable items I need? 'Cause I don't want to get caught part way through and get told - Oh sorry, that part is 6 weeks from order or whatever!

redvers · Fri Jul 13, 2012 9:03 pm

Hi Marius

Thanks I did. Just need to sort out the nipple.

looked at the Gen 3 manual on the system and now have a ltiile better idea of what I have to do still.

Andrew, the top chain is simple, but I have not done the racket yet. Mine is at 208000, so your's should be simmilar to mine in build up

redvers · Sun Jul 15, 2012 9:15 pm

Hi, an update on the progress.
Marius, thanks for the advice. It made stripping much easier. Some advice to all who intend doing this, lots of stripping and patience

Made a 19 mm ring spanner with an open end for the fuel pipes on the pump side. Could not part the brackets holding the pipes together, but pried them apart later as this helps when re installing. The manifold did not want to come loose, so a little help from a rubber mallet and she eventually moved. Replaced the old gasket as this was hard
Some pics before cleaning

: dirty inlet

: cylinder head side

: stripped inlet side

Started to re assemble this afternoon and was very anxious to see if she will start, so I just connected all the components needed to start. Did not need to remove the tapper cover to install fuel pipes, just a little oil, some movement and patience.

Did not connect intercooler, egr or all the covers and brackets.
Replaced the oil pressure sensor. Noticed a small difference here

: old versus new sensor

: oil pressure sensor

Some pics of clean items before assembly

: cleaner manifold

: clean throttle body

Now came the test to see if she will come back to life. primed the filter pump. Turned the ignition and she only cranked over. Did not want to start.
I then remembered that I had not tightened the injector pipes totally.

Did this and purred to life on the first swing.

All be it very noisy due to no egr and intercooler pipes. No leaks.
Very happy and relieved as this is my first diesel engine and lots to learn about them. Idling was normal and throttle responsive. Did not take a test drive.
Now I can continue with the service and connect all the components and covers.
I noticed that the intercooler pipe had been touching the pump pulley and was worn through. Priced this from the agents and at R 1000 rand, I have decided to make an alternative solution. Will see if I can split the pipe and install a stainless steel centre section

4ePikanini · Sun Jul 15, 2012 9:38 pm

Thats a weird overflow bottle you have there. Looks like a VW part. Mine doesnt look like that.

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redvers · Mon Jul 16, 2012 8:10 am

That is a VW part. Previous owner installed it and I don't know why.

andrew.ashton · Tue Jul 17, 2012 4:47 pm

Hi redvers / Marius,

Sorry to be a pita.

Looking at p15-8 of workshop manual this is the list of non-reusables - might be useful for anyone else contemplating this job.

Do I have all necessary items and have I listed items that are unnecessary?

1. Inlet manifold gasket (applied with no sealant?)
2. Set of 4 injection pipe seals (adequately lubricated on assembly).
3. Intake to throttle body gasket. (Can I use a form in place liquid gasket maker here?)
4. Throttle body to inlet manifold gasket. (Can I use a form in place liquid gasket maker here?)
5. ATF level gauge seal (do I really need to remove that?)
6. Engine oil level gauge seal (do I really need to remove that?)
7. Tappet cover gasket (applied with no sealant?)
8. Boost air temperature sensor seal (do I really need to remove that?)

Fluids required:
1. Inlet manifold stud sealer (a la Locktite)
2. Brake / engine cleaner.
3. Form in place gasket maker?

Heater T-pieces
Where are these located - you have got me worried! I thought I would see them on P14-7 of workshop manual.

I would value your feedback.