How To - Removing Inlet Manifold (Diesel)

Jakg · 10th January 2012, 16:58

Remove the engine cover (3 bolts):

Remove the air intake (2 screws and it slides off) - if yours is unmodified you may have the bellows to deal with as well (another 4 bolts):

Remove the following:
1 - Captive bolts (x8)
2 - Nuts (x4) - you might need a long reach socket for this
3 - Bolt (x1) - be careful not to lose the washer!
4 - Rubber wiring grommet (x1), just pops out
5 - MAP sensor plug (x1) - push the metal clip in and pull the plug down
6 - Bolts (x4) - I have an EGR bypass, so yours may look slightly different, but the bolts the same. You may find it easier to remove the hose (one jubilee clip) for access.

Now to remove, simply pull up. There are 8 (orange) gaskets - they will probably be solid (thanks to the soot) but make sure you don't drop them into the engine!

You might find it doesn't want to move, but it will - it's just years of soot build up holding it in place. Rocking should loosen it, as well as showing you it's not still bolted in!

Haynes recommend replacing the gaskets, but they are ~£10 each (yes, £10 for what is basically an O-Ring of which there are 8!) so I didn't bother.

You should be left with this (minus the tape):

And the inlet manifold itself (you can see where the gaskets would be - I put them out of the way for safe keeping):

Refitting is the reverse of removal - but be careful on the nuts, the bolts they go over aren't very strong and it's very easy to break the bolt in half!

Disclaimer:
You are responsible for any work or modifications carried out on your car and you undertake any such work at your own risk.
The 75 and ZT Owners Club nor the original author of this How-To can be held liable for anything that may happen as a result of you following this How-To

75tourer · 10th January 2012, 20:53

Good how to- will save this.
I'm guessing you were taking it off to clean the gunk out. How are you planning to clean it?. I used carburretor cleaner on my EGR and the gunk from that was a nightmare- took a couple of weeks until my hands were clean again. When cleaning I'm guessing the MAP sensor is housed in the manifold- how can you clean the manifold without contaminating the MAP?- Cheers

Jakg · 10th January 2012, 21:01

Quote:

Originally Posted by 75tourer

Good how to- will save this.
I'm guessing you were taking it off to clean the gunk out. How are you planning to clean it?. I used carburretor cleaner on my EGR and the gunk from that was a nightmare- took a couple of weeks until my hands were clean again. When cleaning I'm guessing the MAP sensor is housed in the manifold- how can you clean the manifold without contaminating the MAP?- Cheers

You can remove the MAP from the manifold with one bolt once it's off the car.

I've been cleaning it all day, and my hands (and the kitchen sink, and the hose, and a screwdriver, and the picnic table, and my favourite bucket...) are covered in ****

I've cleaned most of the **** off, but I've thrown in the towel and got my Dad to try some industrial degreaser at his work...

EDIT - Imagine a massive EGR, with a lot less access...

BRITRICH75 · 10th January 2012, 21:56

What a fantastic "How to"... Makes me almost wish I had a diesel Conny SE instead of a petrol one... Rich.

Mike Noc · 10th January 2012, 22:11

Quote:

Originally Posted by BRITRICH75

What a fantastic "How to"... Makes me almost wish I had a diesel Conny SE instead of a petrol one... Rich.

Not as much as when you are filling up at the petrol station though Rich?

Mike

ChestersDad · 11th January 2012, 19:13

Really excellent "how to" Jakg

What I, for one, always wanted to know but was too afraid to ask (and to have a go at - until now!)

Many thanks!

(Now waiting to be similarly impressed with the cleaning procedural piccies!)

MarkS · 20th May 2020, 12:04

Quote:

Originally Posted by Jakg

You can remove the MAP from the manifold with one bolt once it's off the car.

I've been cleaning it all day, and my hands (and the kitchen sink, and the hose, and a screwdriver, and the picnic table, and my favourite bucket...) are covered in ****

I've cleaned most of the **** off, but I've thrown in the towel and got my Dad to try some industrial degreaser at his work...

EDIT - Imagine a massive EGR, with a lot less access...

How do you clean the manifold
Where does the manifold need cleaning ?
And with what cleaning fluid ?
How long should one allow for cleaning ?

Odd Job · 20th May 2020, 12:12

I'm interested to know what everyone uses to clean out this manifold please?
I've got my "spare one" in a bath of traffic film remover at the moment.
It's semi worked. It's been in a bath of the stuff for nearly two seeks now.
I've also used Mr Muscle, carb and brake cleaner, BBQ cleaner, I'm considering using petrol, but not really sure thats the best idea.

cbr1100xx · 20th May 2020, 13:37

Oven cleaner in a bag overnight seems a favourite

Stan

CapnAndy · 2nd December 2016, 14:42

Many thanks for your comprehensive instructions. I had to remove the manifold while doing the inline thermostat modification and your instructions helped a lot. Result was I've cleaned out the manifold and EGR and it's giving me much better engine performance. I'd recommend that anyone doing the inline Mod should bite the bullet and remove the manifold, it makes things much easier and you're less likely to break the plastic connection on the radiator hose which is what happened to me..

10th January 2012, 16:58	#1
Jakg This is my second home N/A Join Date: Feb 2010 Location: Suffolk Posts: 6,867 Thanks: 0 Thanked 397 Times in 302 Posts	How To - Removing Inlet Manifold (Diesel) Remove the engine cover (3 bolts): Remove the air intake (2 screws and it slides off) - if yours is unmodified you may have the bellows to deal with as well (another 4 bolts): Remove the following: 1 - Captive bolts (x8) 2 - Nuts (x4) - you might need a long reach socket for this 3 - Bolt (x1) - be careful not to lose the washer! 4 - Rubber wiring grommet (x1), just pops out 5 - MAP sensor plug (x1) - push the metal clip in and pull the plug down 6 - Bolts (x4) - I have an EGR bypass, so yours may look slightly different, but the bolts the same. You may find it easier to remove the hose (one jubilee clip) for access. Now to remove, simply pull up. There are 8 (orange) gaskets - they will probably be solid (thanks to the soot) but make sure you don't drop them into the engine! You might find it doesn't want to move, but it will - it's just years of soot build up holding it in place. Rocking should loosen it, as well as showing you it's not still bolted in! Haynes recommend replacing the gaskets, but they are ~£10 each (yes, £10 for what is basically an O-Ring of which there are 8!) so I didn't bother. You should be left with this (minus the tape): And the inlet manifold itself (you can see where the gaskets would be - I put them out of the way for safe keeping): Refitting is the reverse of removal - but be careful on the nuts, the bolts they go over aren't very strong and it's very easy to break the bolt in half! Disclaimer: You are responsible for any work or modifications carried out on your car and you undertake any such work at your own risk. The 75 and ZT Owners Club nor the original author of this How-To can be held liable for anything that may happen as a result of you following this How-To Last edited by Dragrad; 30th July 2015 at 20:56..

11th January 2012, 19:13	#6
ChestersDad Still 75less :-( 1988 Defender 90 Join Date: Jun 2011 Location: Carmarthenshire Posts: 531 Thanks: 15 Thanked 93 Times in 37 Posts	Excellent! Really excellent "how to" Jakg What I, for one, always wanted to know but was too afraid to ask (and to have a go at - until now!) Many thanks! (Now waiting to be similarly impressed with the cleaning procedural piccies!) __________________ Don't save for the future as someone else will lose it for you!

20th May 2020, 12:12	#8
Odd Job Gets stuck in MG ZT 2.0 cdti Join Date: Aug 2019 Location: Derby Posts: 909 Thanks: 298 Thanked 191 Times in 149 Posts	I'm interested to know what everyone uses to clean out this manifold please? I've got my "spare one" in a bath of traffic film remover at the moment. It's semi worked. It's been in a bath of the stuff for nearly two seeks now. I've also used Mr Muscle, carb and brake cleaner, BBQ cleaner, I'm considering using petrol, but not really sure thats the best idea. __________________ ….And the latest thing to break is..... ### MG STANDS FOR "MY GREMLIN" !!!

20th May 2020, 13:37	#9
cbr1100xx Gets stuck in VW touareg Join Date: Mar 2015 Location: dunsop bridge Posts: 870 Thanks: 225 Thanked 414 Times in 235 Posts	Oven cleaner in a bag overnight seems a favourite Stan __________________ WE WERE BOTH BORN ON THE 4th of JULY CAR DIED 15/11/2022---I'M STILL GOING (JUST)

2nd December 2016, 14:42	#10
CapnAndy Newbie Rover 75 tourer Join Date: Sep 2016 Location: Glasgow Posts: 2 Thanks: 0 Thanked 0 Times in 0 Posts	Many Thanks. Many thanks for your comprehensive instructions. I had to remove the manifold while doing the inline thermostat modification and your instructions helped a lot. Result was I've cleaned out the manifold and EGR and it's giving me much better engine performance. I'd recommend that anyone doing the inline Mod should bite the bullet and remove the manifold, it makes things much easier and you're less likely to break the plastic connection on the radiator hose which is what happened to me..

10th January 2012, 20:53	#2
75tourer Loves to post Rover 75 CDT Tourer Auto Join Date: Nov 2010 Location: Dundee Posts: 285 Thanks: 40 Thanked 13 Times in 9 Posts	Good how to- will save this. I'm guessing you were taking it off to clean the gunk out. How are you planning to clean it?. I used carburretor cleaner on my EGR and the gunk from that was a nightmare- took a couple of weeks until my hands were clean again. When cleaning I'm guessing the MAP sensor is housed in the manifold- how can you clean the manifold without contaminating the MAP?- Cheers

10th January 2012, 21:56	#4
BRITRICH75 Avid contributor Rover 75 2.0 v6 Connoisseur SE Join Date: Aug 2011 Location: WREXHAM Posts: 112 Thanks: 0 Thanked 0 Times in 0 Posts	What a fantastic "How to"... Makes me almost wish I had a diesel Conny SE instead of a petrol one... Rich.