Right - closed off this intake manifold clean up project and the paj is back on the road - seemingly none the worse for wear. I now know where a whole lot more stuff is hidden under the bonnet. Have to admire the engineers who design all this stuff and fit it into such a small space.
It's a great challenge if you enjoy 3-dimensional jigsaw puzzles and those manuals can be misleading. For instance they have you fitting the manifold cover before you refit the dip-stick tubes. You can't possibly do that - so you end up doing things twice. I think that's what 4ePikanini meant when he said its easier the second time!
Anyway (thanks to SimonB and his picture magic) here are some pics:
- Head ports cleaned up and injector pipe seals removed (decided to replace because they had been weeping oil)
- New injector pipe seals and inlet manifold gasket in place
- It's a big job to get an oil burners inlet manifold back like this - compare this pic with the before pic
- So this is what was hidden under all the gunk at the EGR inlet port of the manifold.
- Inlet manifold reinstalled.
- Injector pipes reinstalled (Oh &^%%&&* forgot to tighten #2 pipe at the pump and ended up doing this twice. Of course #2 pipe has to be fitted before any of the others ...)
- All ready for the tappet cover. See how nice and clean Delo 400 keeps the top end.
You can see the high res images (and a few more, including the before and after images) on my flickr site:
Pajero 3.2 Di-D pre-common rail inlet system
It wasn't too difficult to clean the throttle and EGR valve but the manifold is another story - and don't do it in the kitchen sink because you may be sleeping with your beloved (pajero) in the garage thereafter. In the end I contracted the cleaning of the manifold out to Alpine Turbo and they got it cleaner than I could.
By the way - this post comes with a health warning - don't try this at home (unless you are into sadomasochism).
