Intake Manifold Questions: Details & FAQs

Hi.

I've now stocked up on all the necessary gaskets and screws for the intake manifold and AGR (exhaust gas recirculation) removal and installation.

Okay, a few questions before I proceed:

The suction seal is not the same on both sides; it has a raised profile - in which direction should the bulge face??

Does the lubricant reach the engine dry, or is it allowed/recommended to use a thicker lubricant?

I have new screws for the bridge and AGR, should they be installed dry or "with something"? I have copper paste available.

Thank you.
m;

Hello.
Install the embossed side outwards (towards the bridge) and ensure a dry fit. The screws were in perfect condition, at least in my case; only the outermost two had a slight amount of surface rust on the head. I installed the screws dry in the threads and applied "Amerilube 56" to the contact surface on the bridge.
I sprayed the two nuts on the AGR pipe connection near the bend with copper spray. There was also significant rust present there. The two Allen screws directly on the AGR valve, used to secure it to the intake manifold, were also dry in the threads and had grease on the contact surfaces.

Best regards, Robert.

To the best of my knowledge, the...
- Profile bulge towards the intake manifold.

- Gaskets are usually applied dry, but I applied a very thin layer of heat-resistant grease to the intake manifold and cylinder head. In my case, the aluminum was slightly corroded, and I don't like that.

- I also applied a very thin layer of grease to the screws, reasoning that those areas wouldn't get hot enough for the grease to burn. I used a heat-resistant grease for this purpose.

I hope you took some nice photos with the digital camera and have already processed them (hehe).
But such hints and a brief guide in the form of a technical article would significantly reduce the number of questions raised about this topic.

Regards,
Woof.

Hi Wutz.

You still owe me one article, don't you?

I haven't done anything yet - I've only bought parts so far. I hope that when I start working on it, I won't get so into the tinkering that I forget about taking pictures .

m;

Hi Martin,

"I'm very interested in that too... I'll be taking apart and cleaning my intake manifold soon. Photos would be very helpful. I might be able to add some later from the ASV (I'll just make my girlfriend take the photos, so I don't have to keep washing my hands)."

Best regards,

Jan.

@dieselmartin

I would definitely not forget to use rubber gloves for cleaning. It might look silly to walk around like Tilly, but the sink (and your wife) will thank you for it.
Since the carbon buildup was very thick on my engine, I got some flat aluminum sheet from the hardware store. I rounded off the front edge slightly and angled it. This creates a perfect scraper that won't scratch the intake manifold. Moreover, the aluminum is very easy to bend, allowing you to reach all the corners.
Instead of using a regular brake cleaner, I used the one from Liquid Moly. It's a bit better (you can tell by the warning labels) and it delivered good results.
Just a small tip on the side.
I haven't gotten around to processing it yet.
1. I don't have a website.
2. I'm still having issues with my Climatronic system.

Regards,
Woof.

Help for Wutz:

1. I don't have Climatronic.
2. I can upload an unlimited amount of data to the internet (so, even 400 GB, if I were to buy a 400 GB hard drive ).

"Consequently," or "Therefore," or "It follows that..."
Please provide me with your drafts, and I will publish them.

"Aluschaber" sounds good, then I at least know why I regularly sort through the steel and aluminum scrap from the university workshop .

m;

hello,
@dieselmartin, here are some pictures of my decommissioning activity from the weekend before last for you to view: http://web.utanet.at/langzaur/.
A 1Z engine, EZ 1/1995, currently with 145,000 km on the odometer. Everything is still original, no tuning or modifications. It runs with 195/60 14" tires and reaches a top speed of just under 185 km/h. Fuel consumption is a maximum of 5.5 liters during fast highway driving. In the illegal area here in Austria ), it's mostly used for short distances (up to about 18 km) in the city. In that case, the fuel consumption is significantly below 5 liters.
"Interestingly, the build-up was mainly in the intake passages of the inner cylinders, with some areas reaching 8mm! The first cylinder showed very little (around 2mm) seepage at the channels."

Best regards, Robert.