Inlet manifold interior wall covered in black shyte - TD27t

[Damz]

As per title, thick, black, oily, gunk everywhere inside the inlet manifold. Scrape a finger along it and you pull out enough to marmite your sandwich....

What causes this, and is it something I should be worried about?

Theres no shaft play in the turbo, and engine doesnt smoke black or blue.

Anything I can do to clean it out, without removing the whole darn thing?

Cheers

[kbushnz]

Ah the dreaded black gunk!
Exhaust Gas recycling valve (EGR).. Puts exhaust gas into inlet manifold.
Crankcase vent. Vented into intake before turbo compressor wheel. Has some oil in it.

Results in what you have got. A mix of oil and soot.

Fix.
Remove / blank off EGR.
Oil catch can for cranckcase vent.

I have done the EGR removal on my Toyota...
Not done oil Catch can but on the cards.
At least its only oily now and not black with soot.

Soot / gunk buildup can obstruck intake and valves.

When my head cracked some 6 years ago, the intake manifold was solid with gunk...only a 10c sized passage. And large bulb of crud on the valve stems. Took ages to wash it out.

Calvin

[Damz]

Cheers mate, I think this motor has already had the EGR blocked, that is if its a pipe that goes from the exhaust manifold, round the back of the block, and into the inlet manifold.

Looks like it might be worth taking the manifold off then for a good clean out?? A 10c size inlet is not quite satisfactory!!

Is the crankcase vent on the top of the head, oppsite end from the oil filler cap?

Cheers again

[tweake]

as above.

a good catch can with some sort of filtering medium in it is recommended for the crankcase breather.
but also don't forget the dust that gets through the airfilter combines with the oil and soot to make the sludge. especially with high flow air filters like K&N.

[Damz]

Is the crankcase vent on the top of the head, opposite end from the oil filler cap?

[sibainmud]

Is the crankcase vent on the top of the head, opposite end from the oil filler cap?

Yip.
I direct mine through copper tube down the chasis rail to behind the front seats. Never into the air filter or pre-turbo.
My manifold was the same when i pulled it of a dead engine, cleaned it spotless, and 2 years, 25,000 k's later, i have just had a look down it lately, there was less than a mm thin layer inside
Now with intercooler and controlled boost, I get a drip every couple of minutes running out the breather tube
Clean it up soon.
Cheers,

[Nivapulledout]

EGR pipe should not deposit alot of gunk back into the intake but not such a biggy if you block it off.(More NOX emissions bad for the ozone we are all getting burnt because of)

PCV (positive Crank ventilation valve) is there for a reason and if working well should not let too much into the intake(sometimes a light smear) the reason they start dumping oil into the intake is normally because they have never been replaced, should be done everytime you do the plugs in a petrol or around every 50k in a diesel. Also need to get to the wire mesh sieve that coalesces the oil mist out of the air flow, sometimes this requires removing rocker cover.

If the PCV is valve is removed and the pipe re-routed, your truck will not only dump twice as many hydrocarbons (clean grean NZ/factor 100 sunscrean) into the air but also drip oil onto the road which leads to slippery conditions on the road when it gets wet. These were the two of the main reasons the PCV valve was made mandatory on cars around 1960.(It was invented during WWII with the need for tanks to ford deep water, it stopped water going up the breather into the engine!!! another thing a catch can/filter will not do)

In my 15 years as a heavy diesel mech I have never seen a sludgy intake with a properly svced PCV system. a slight smeer of oil is fine. Thick gooo was always related to jammed PCV and gunked/removed Wire mesh filter.

Do it right save us the sunburn and yourself the hassle of modifying it and just buy a new PVC valve and clean the wire mesh, now that your intake has gunked you will need to remove and degrease it.

Just my 2 cents

[kbushnz]

You will find that some small Diesels dont have a PCV valves...
The 1KZTE doesnt... Just vents from the rocker to the turbo inlet.
No valve.
Calvin

[tweake]

EGR pipe should not deposit alot of gunk back into the intake but not such a biggy if you block it off.(More NOX emissions bad for the ozone we are all getting burnt because of)

PCV (positive Crank ventilation valve) is there for a reason and if working well should not let too much into the intake(sometimes a light smear) the reason they start dumping oil into the intake is normally because they have never been replaced, should be done everytime you do the plugs in a petrol or around every 50k in a diesel. Also need to get to the wire mesh sieve that coalesces the oil mist out of the air flow, sometimes this requires removing rocker cover.

If the PCV is valve is removed and the pipe re-routed, your truck will not only dump twice as many hydrocarbons (clean grean NZ/factor 100 sunscrean) into the air but also drip oil onto the road which leads to slippery conditions on the road when it gets wet. These were the two of the main reasons the PCV valve was made mandatory on cars around 1960.(It was invented during WWII with the need for tanks to ford deep water, it stopped water going up the breather into the engine!!! another thing a catch can/filter will not do)

In my 15 years as a heavy diesel mech I have never seen a sludgy intake with a properly svced PCV system. a slight smeer of oil is fine. Thick gooo was always related to jammed PCV and gunked/removed Wire mesh filter.

Do it right save us the sunburn and yourself the hassle of modifying it and just buy a new PVC valve and clean the wire mesh, now that your intake has gunked you will need to remove and degrease it.

Just my 2 cents

i was going to say where they hell have you been for the last 20 years, but truck mechanic says it all.
trucks and light diesels are totally different animals.

most of the light diesels i know of do not run PCV valves, they run straight to engine intake. the older patrols are an exception, they run a valve on top of the rocker cover. however they are also UD industrial motors.

while i agree the crankcase vent should not vent to the ground a lot of trucks do that from factory. trucks have different emission rules than light diesels.

egr sooting up of intake is the norm with light diesels, even from brand new. oil from breather is also much the norm tho some vehicles are really bad for it. it could well be the manufacture didn't spend the extra $2 for a proper system, but thats what light diesels are like. they are cut down stripped out to the cheapest that will do the job and last long enough to get out of warranty.
truck/industrial engines have all the good stuff built into them. i see they are starting to come out with catch cans with replaceable filters in them on trucks now.

[Nivapulledout]

Ok me bad, yes Most of my work was on large Diesels and military equip. I thought the small ones should be similar. Now I am on Marine all the engines use a Oil spinner between the air cleaner and turbo, this creates a vortex on the intake so all the oil in the air is thrown out onto a mesh where it collects and drains back to sump. works really well till the drain blocks.
Ignore my previouse comment then

[darinz]

One thing you've all forgotten. If the crank case / rocker cover vent is into the intake then when you roll over or onto your side. All the oil that gets into the head runs into the the engine. You then get it running away. Fitting a simple catch can, means if you roll you'll only have bodywork to fix not a motor to replace as well.

[flyingbrick]

just pull the manifold off and flush/soak it in petrol as best you can.

I got a spare manifold for my td42 which was egr equipped and MAN was it filthy inside.

[tweake]

One thing you've all forgotten. If the crank case / rocker cover vent is into the intake then when you roll over or onto your side. All the oil that gets into the head runs into the the engine. You then get it running away. Fitting a simple catch can, means if you roll you'll only have bodywork to fix not a motor to replace as well.

could point, tho these catch cans are often partly filled with oil so in a roll over its going to get a mouth full of oil.

[IcedJohnno]

just pull the manifold off and flush/soak it in petrol as best you can.

egr equipped and MAN was it filthy inside.

When I ported my new head, it took a week of soaking my inlet manifold in petrol in a 20 litre drum and scrubbing hard with a big bottle brush to get the job done properly.
Daily scrubs after the first 2 days.....

[Damz]

just pull the manifold off and flush/soak it in petrol as best you can.

I got a spare manifold for my td42 which was egr equipped and MAN was it filthy inside.

Exactly what I did this morning. Had to soak and scrub with a dish brush but came up farkin stunning inside

[Shane]

just pull the manifold off and flush/soak it in petrol as best you can.

egr equipped and MAN was it filthy inside.

When I ported my new head, it took a week of soaking my inlet manifold in petrol in a 20 litre drum and scrubbing hard with a big bottle brush to get the job done properly.
Daily scrubs after the first 2 days.....

A friend took his TD42(had EGR) manifold off to do just that,cleaned half a port,stuff this and used a spare I had which has no EGR and was pretty clean,blocked rest of the system off.

Shane

[flyingbrick]

One thing you've all forgotten. If the crank case / rocker cover vent is into the intake then when you roll over or onto your side. All the oil that gets into the head runs into the the engine. You then get it running away. Fitting a simple catch can, means if you roll you'll only have bodywork to fix not a motor to replace as well.

could point, tho these catch cans are often partly filled with oil so in a roll over its going to get a mouth full of oil.

You don't have to have the catch can venting back into your plenum.

[tweake]

You don't have to have the catch can venting back into your plenum.

true.
i did run mine open. i got lots of oil smell (the filter in it dosn't stop 100% of the oil), you could plump it underneath but that drops oil all over the road which is think is stupid.
also the catch can got very hot. with it connected to the intake it stays reasonably cool. if it gets to hot it could melt the filter!

[darinz]

I ran a plastic catch can that and it never melted non did the foam filter on it.
It was setup so when you turned the motor off any oil in it drained back to the rocker cover.
Sure it put out a small amount of oil but the vent of mine was right against the bonnet ad it only ever had a oil stain on the bonnett. It never ran of dripped of it.
The fumes were pretty irrelevant too.
And take into account this was on an old 200,000km motor that was running 21psi and got thrashed. It had the rev limit wound up to 5200rpm and it was used at those revs.

[flyingbrick]

interested as to how ya made it drain back when the motor was off. Just a one way valve?