The blow by hose on my OM602(NA) was cracked and allowed sludge to accumulate in the intake and the intake ports, all over the intake valves too. Is there any safe way to clean both the manifold and those ports? I had the intake off to ream the glow plug holes, service the injectors (being rebuilt by greazzer), and check the plastic fuel hard lines (thankfully no cracks or chaffing) and just noticed how nasty it was.

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Current: 1975 450SEL, 83 300D, 88 Yugo GVX, 90 300D OM603 swap, 91 F150 4.6 4v swap, 93 190E Sportline LE 3.0L M104 swap, 93 190E Sportline LE Megasquirt, 03 Sprinter, 06 E500 4Matic wagon.

The vent hose is supposed to send crank cases vapors into the turbo and downstream. A crack can only reduce the flow. EGR bakes the vapor onto the intake tract. Biodiesel can safely clean the sludge but it'll need mechanical help. If you choose harsher chemicals, make sure they're safe for the type of materials being cleaned. Someone might know whether Easy Off is safe and effective. Be careful cleaning the ports as anything that comes loose can fall into the combustion chamber.

Sixto
87 300D

off the car soak in apple cider vinegar on or off the car use carbon off you can find it at a restaurant supply, if you have never used carbon off you will be amazed.

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"NEW" 1984 300D TD needs some love

I bought a huge plastic rectangle tub which was pretty thick (heavy duty) from Michaels on sale for $10.00. I tried a 5 gallon bucket and no luck as it was not big enough. As the other posters said, take it off and let it soak. Make sure that whatever you use, it does not contain any caustic sodas or acids or you will or could damage the aluminum. Get a bottle brush at the dollar store also. The only problem was being able to pick up the plastic container and drain it. The key was to laddle it out with a plastic tub. Then, I dropped $2 bucks in quarters at the self serve car wash and blasted mine right over the grate, being careful not to be back blasted. Wear crappy clothes if you go that route since that black crap goes everywhere and it's not coming out.

Put on some rain gear and a Face Shield when pressure washing out the manifold. I used a Steam Cleaner from work, and it is much higher pressure than a 25¢ car wash. I had that crap blowing everywhere. ......But it was sure clean afterwards.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

but soak in a vat of diesel first.

Hey W123FanMan --

Sent you a PM and email

I did the same thing after having a shop run it through their cleaner 3 times and finally got it clean...it's messy!!!

I took the manifold to a local engine rebuild shop and left it there for about a week. For an hour's labour charge it came back clean as a whistle, inside and out.

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'98 E300 DT
'87 190D 2.5 turbo RIP
'92 S500 Sold
'03 3.2TL-S A-Spec

I cleaned the intake on my OM602 this weekend when I changed the glow plugs. Took about 5 minutes with no mess. That gunk in there is flameable. Put a torch just inside one end then use your air compressor slowly to accelerate. Flames shoot out of all 5 ports for about a minute. After it cools a bit, wash the soot out with water.

If you don't disable your EGR, it will gunk up again.

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You can't always get what you want, but if you try sometime you just might find you get what you need.

So I would block off vacuum to the EGR or what? I see more info on how to do it on other engines, not the NA OM602 though, but I assume its basically the same?

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Current: 1975 450SEL, 83 300D, 88 Yugo GVX, 90 300D OM603 swap, 91 F150 4.6 4v swap, 93 190E Sportline LE 3.0L M104 swap, 93 190E Sportline LE Megasquirt, 03 Sprinter, 06 E500 4Matic wagon.

Is that too much heat for the manifold? No idea, just asking.

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"Senior Luna, your sense of humor is still loco... but we love it, anyway." -rickymay ____ "Your sense of humor is still loco... " -MBeige ____ "Señor Luna, your sense of humor is quite järjetön" -Delibes

1982 300SD -- 211k, Texas car, tranny issues ____ 1979 240D 4-speed 234k -- turbo and tuned IP, third world taxi hot rod

2 Samuel 12:13: "David said to Nathan, “I have sinned against the Lord.” And Nathan said to David, “The Lord also has put away your sin; you shall not die."

I've done it 2 times now without any warping or cracking. Not really heating the intake, just igniting the gunk on the inside while blowing alot of air across it. The intake gets hot but not enough that you know its hot without touching it. Proceed at your own risk, but I personally can't see how it could cause a problem.

It's definately the easiest / cleanest / fastest / cheapest method I've seen presented.

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You can't always get what you want, but if you try sometime you just might find you get what you need.

Locate the EGR and remove it leaving an oval'ish opening into the intake manifold. 2 options, either make a block off plate to fit the opening (I think the ones sold for the OM617's are the same size) and throw away the EGR or use the gasket as a pattern and cut a thinner block off piece (I used copper roofing flashing) and replace the EGR with this underneath.

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You can't always get what you want, but if you try sometime you just might find you get what you need.

There is a bunch of video`s on You Tube of the VW TDI manifold cleaning by fire. I was going to post this when the thread first started, but figured I would get flamed from posting it.

If you are worried about too much heat, squirt some water on the manifold like this guy.


Redneck VW TDI Intake Manifold Cleaning - YouTube


Charlie

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works