Pajero Owners Club of South Africa

Hi all,

So while my Paj is resting in the garage waiting for a new radiator it seems like a good opportunity to strip and degunk the inlet manifold. I can see from the EGR valve side that it looks like the Black Hole of Calcutta. I do not have EGR blanked off - but will blank off after this cleanup.

Any tips to do this without breaking too much?
As far as I can see I have to remove the diesel injector feed pipes (this is a pre-common rail engine).

Do I need any special tools?
Any impossible to loosen (or even worse, impossible to tighten after successfully loosening fixing points?)
Any special muti required.
Do I really have to replace the injection pipe seals (as shown in the manual P15-9)?
etc.

There was a write up done by 4ePikanin some time ago on this IIRC. I will try and find it and post here. As far as I remember there was a lot more work to it. This is one of the reasons why mine are still untouched.

CATS

Sent from my GT-I9500 using Tapatalk 2

It is a pain in the proverbial but the second time roud should be easier.

The top cover on the diesel pump need to be removed for access.

I believe the glowplug rail needs to come off
Undo the injector union nuts (no need to replace seals)
unbolt all the things you see attached to the manifold like boost pipes etc
unbolt the manifold and remove

CATS wrote:There was a write up done by 4ePikanin some time ago on this IIRC. I will try and find it and post here. As far as I remember there was a lot more work to it. This is one of the reasons why mine are still untouched.

Thanks CATS,

Probably this thread: 3.2 DiD Inlet manifold cleaning

4ePikanini wrote:It is a pain in the proverbial but the second time roud should be easier.

The top cover on the diesel pump need to be removed for access.

I believe the glowplug rail needs to come off
Undo the injector union nuts (no need to replace seals)
unbolt all the things you see attached to the manifold like boost pipes etc
unbolt the manifold and remove

Thanks Marius,

Any tips on removal and installation of engine oil level and ATF level dip stick tubes (level gauges and guides as the manual refers to them)? Do they just pull out? And how to align them during refitting?

I remember someone showing the oil level sensor removal and installation on here.

https://www.pajeroclub.co.za/forum/view ... 28&p=25652

https://www.pajeroclub.co.za/forum/view ... =24&t=3604



The ATF tube is a two part tube. The bottom tube is part of the pan.

4ePikanini wrote:I remember someone showing the oil level sensor removal and installation on here.

https://www.pajeroclub.co.za/forum/view ... 28&p=25652

https://www.pajeroclub.co.za/forum/view ... =24&t=3604



The ATF tube is a two part tube. The bottom tube is part of the pan.

Thanks Marius,

In the meantime I worked it out!

Engine oil dipstick guide has one bracket hidden behind intake manifold cover (part 12 on P15-8).
ATF oil dipstick guide has two brackets accessible from under the car - one (13mm AF) just above the starter solenoid and one (14mm AF) on the bell housing.

BTW you DO probably need to remove the glowplug supply rail to get a proper grip on the rear cylinder injection pipe nut.

Hmm,

Beginning to feel like that time when I was 7 years old and took my dad's Remington typewriter to pieces (never to be successfully reassembled!).

Anyway - way beyond the point of no return.

That's such an innocent little diagram on P15-9 Removal Service Point - Injection pipe removal.

How do you get any spanners on the back nuts!?

Success! (If removing the manifold without visibly breaking anything can be seen as a successful partial outcome).

So now I have a garage full of dirty inlet parts ready for cleaning. And a whole lot more parts that had to be removed to get the manifold off.

This is what I have found so far for anyone contemplating this task:
1. It is not trivial.
2. There are a couple of points not mentioned on P15-9 of the manual:
2.1 The injection pump cover (see P13C-56 item 14) is bolted to the inlet manifold so it certainly needs to be loosened at least to finally get the manifold off.
2.2 There is no mention of the fuel return pipe (see P13C-50 item 8) in P15-9 inlet manifold removal - but it is also bolted to the inlet manifold underneath -0 about opposite cylinder #3.
2.3 It is easier to get spanners to remove injector pipe #3 from underneath the car.

I will post a few pics of what I found.

So I really wanted to upload some pics (Upload Attachment, Browse, select one jpg file, add a one line file comment, click on Add the file) - but it doesnt matter whether I try Chrome or Internet Explorer - all I get is a message like:

Fatal error: Allowed memory size of 33554432 bytes exhausted (tried to allocate 17152 bytes) in /home/pajerxga/public_html/forum/includes/functions_upload.php on line 297

And the pics are just JPG of small size (about 800kB each).

Any thoughts?