Engine: D5: cleaning inlet plenum/manifold

[s60.i@n]

Anyone done this ?
In an idle moment too the inlet pipe that goes from the egr mixer to the inlet plenum? off an noticed it was coated with a fair amount of *nasty* oily sooty gunk. Cleaned the pipe and egr mixer. But it looks like the inlet plenum will also be affected..

My main concerns are the fuel pipes from the rail to the injectors, vadis says to replace them.. also is there a gasket between the cover and the block ?

Gloves, hazmat suit, truckload of kitchen roll and gallons of white spirit at the ready

Cheers

[BobD5]

I had this recently, my haynes manual scared the besjeeesus out of me by saying my turbo had failed. I did a search here and it sounds quite common. I recon with mine it was due to the garage overfilling my oil and the some oil was passing in to the inlet through the breather pipe.

WEAR GLOVES:

Here is what I did, I removed the rubber hose that goes to the inlet and the metal mixer it attaches to (the metal pipe that connects to the rubber hoses and the exhaust thingy Y Shaped ish). Anyway I cleaned then in a bucket of fairy liquid water and thoroughly dried them off, put it back together and bought some 10k boost Diesel. i ran this treament through the intake after the air mass meter by moving the hose to allow me to spray in to it. My car feels alot better now alot of the crap has blown out the back. I also filled the tank and added some red x diesel injector cleaner. I added the recommended amount and it is supposed to be safe for the common rail engine.

Oh, one more thing. WEAR GLOVES. I was a week cleaning my hands.

[s60.i@n]

When I was cleaning the pipes out I decided I *really* needed gloves, but could only find 2 right hand "marigolds" in small size.. d`oh,, lol

[DieselDoNicely]

Originally Posted by BobD5

I also filled the tank and added some red x diesel injector cleaner. I added the recommended amount and it is supposed to be safe for the common rail engine.

Never used the stuff, is that like Dr Goods potions.

DDN

[chieftiff]

Hi,

I have done what you ask about. If you do a search under egr valve I think you'll find it but in a nutshell.
No you don't need new fuel pipes just ensure they are correctly aligned as you tighten them up.
Use the silicone instant gasket (halfords) when you replace the plenum top.
I also blanked off the EGR so you don't get the exhaust carbonising the oily mixture.
The build up of carbon in the plenum is quite frightening but cleans off ok. Just put rags down the inlets so nothing falls down them as you clean.

have fun

Dave

[S60-MBS]

Hi Guys any pics on where these parts are located might give it a try myself..

[s60.i@n]

Thanks !

Originally Posted by chieftiff

Hi,

I also blanked off the EGR so you don't get the exhaust carbonising the oily mixture.

Now, this seemed an excellent idea to me, and I tried it, but it was flagging up "High emissions service required" messages.. These go away, but I`m sure are logged somewhere..

(2004 S60 D5)

[chieftiff]

Hi again,

I have heard people getting error messages but I didn't, maybe because mine is a 2002. I have run for about 5k with it blanked and intend to have another look at the plenum in the summer and see what has occurred since the clean. Meanwhile I am worried about my air con compressor which seems a bit noisey as I can hear it cutting in from the cabin???? Any thoughts.

Dave

[hobbyhorse]

Originally Posted by chieftiff

Hi again,

I have heard people getting error messages but I didn't, maybe because mine is a 2002. I have run for about 5k with it blanked and intend to have another look at the plenum in the summer and see what has occurred since the clean. Meanwhile I am worried about my air con compressor which seems a bit noisey as I can hear it cutting in from the cabin???? Any thoughts.

Dave

The aircon on our `53 V70 D5 has always cut in with a `thonk` (previous Passat used to run all the time)

[s60.i@n]

I can hear the compressor kicking in too, though its not worryingly noisy..