24v 80 series egr crap

[karl webster]

Following what another forum member has had recently by using a product to clean his intake. Then finding issues with his engine. After opening the engine up he found issues.

This is has been long overdue for me. I've got egr blanking plates on the shelf and I've been waiting to get time to sort it. My egrs and inlet is wet with oil now.

I grabbed a spare Inlet pipe off the shelf so I can clean it before I fit it to my truck. Didn't get a photo before but thought I'd upload a pic of the amount of crap that was in there. Still more but I'll do that with some kind of cleaner.

 

[karl webster]

I think I'm going to find the one that's on my truck now far worse than what was in the one that I've just cleaned.

 

[clivehorridge]

Bloody 'ell Karl, I guess that's what you get from smokin' foreign fags

 

[karl webster]

Bloody 'ell Karl, I guess that's what you get from smokin' foreign fags

Lol Clive. Holly's bro gave me them. I never smoke fags. I'm a Rolly man

 

[Mblinko]

The crap that's in there is amazing. I put plates on mine and found that the pipe diameter on the EGR has been reduced to a quarter of its original size. Should have taken a photo really.

 

[StarCruiser]

Bloody 'ell Karl, I guess that's what you get from smokin' foreign fags

The irony wasn't lost on me either. [emoji4]

I read on a forum Nitromors cleans it out pretty well.

 

[karl webster]

I've seen photo similar to you describe before Mark. Think ill find that the one on my truck will be like that. Ill upload photo once I take it off.

 

[Tommy345]

I did a 100 series last week that had done 360,000, customer was complaining that he was down on power, was obviouse why once it was in bits

 

[karl webster]

I'm getting rid of the heater part of the inlet as well as that must restrict air flow a fair bit as well. 360 not bad for a 100 Tom. Highest milage one Ive heard of so far. Has it been trouble?

 

[Tommy345]

The millage is getting up there, still plenty of life left in it, drives like its done 100,000 now ive been threw it. customer has it from new and never had any trouble with it, he owns two and they get used every day.

Ive never cleaned one out and found a pack of fags, that is a first

 

[karl webster]

This morning in the rain I swapped the inlet pipe over for the one that I cleaned. A heads up for people interested I used oven cleaner. Spray loads in there then leave for 20 min and pressure wash out. I repeated this a few times and also used an old toothbrush.

After taking my original cross over pipe off I found that the actual inlet manifold is a complete mess with the same stuff. I'm going to do the job again and have an inlet manifold cleaned and ready to fit.

ive fitted the egr plates. One of the bolts that go into the exhust manifold have snapped off. Looks like it was over tightened in the past.most of the bolt is rusty where its snapped.

So to conclude. Not a great finish to the morning after getting soaked on the drive. Plus though,it does feel more responsive. Will be better once I've re done the job again though.

 

[dellboykev]

Don't bother cleaning the inlet just spray some egr cleaner through it, who needs Pistons when when they have a shiny inlet manifold

 

[karl webster]

Don't bother cleaning the inlet just spray some egr cleaner through it, who needs Pistons when when they have a shiny inlet manifold

Simple mistake mate. Your issue was the main reason for me posting this for anyone thinking of doing what you did. I was surprised at how much crap was in there.

Better to do as I have done by taking them off and cleaning them. I may do a part exchange type thing so people have nice clean parts ready to fit

 

[Towpack]

That black crud will have built up all the way to the back of the inlet valves. My cross over pipe was the same, as was the inlet manifold. I scraped and cleaned out what I could from the manifold in situ. If I ever have it off for some other reason I'll give it a thorough clean and degrease. At least with the EGR blanked off it won't get any worse. Looking at the state the inlet tract can get in with this build up is why I'm very sceptical of the spray cleaners that are supposed to clean the system with the engine running and sending all the dissolved crud through the motor and 'burning' it off. JMO

 

[Tommy345]

If I for some reason end up owning another 24 valve 80 or a 100 series removing and cleaning the inlet manifold will be one of the top job so the list. Done quite a few recently for customers, that EGR system is a terrible thing

 

[karl webster]

If I for some reason end up owning another 24 valve 80 or a 100 series removing and cleaning the inlet manifold will be one of the top job so the list. Done quite a few recently for customers, that EGR system is a terrible thing

The inlet manifold really is nasty.

 

[StarCruiser]

Just a thought, rather than using oven cleaner Karl, how about trying EGR cleaner with the part in a bucket (I.e. Not in the piston wrecking position[emoji53]) and see what the stuff does.

 

[karl webster]

I had a look on the web Rich. Loads of people recommended oven cleaner. I may give the other stuff a go when I clean a inlet manifold ready for fitting.

 

[frank rabbets]

It is not possible to clean parts of these engines without taking them apart. Further more there is risk of serious damage. Just imagine what would happen if Karls carbon had broken loose due to in situ cleaning and gone into the combustion chamber. There is no room in there.

The further you go down the inlet tract the harder the carbon gets. On the back of the valves it's diamond hard and difficult to get off even spinning in a lathe and using coarse paper. I chip the worst off with a round bar first. There is no way an engine cleaner would do that. The same diamond hard carbon is found on the tips of the injector and around their tips in the combustion chamber. The injectors work at such a high pressure that they are clear or partly blocked by diamond hard carbon and again injector cleaner is just a joke.

As the valve timing and combustion are not completely perfect some of the carbon on the backs of the inlet valves is caused by fuel mixture burning in the inlet chamber port. I get that on engines whether petrol of diesel, old or modern, although better recently due to better engine design, fuels and oils. There would still be build up especially on the valves even without the egr's.

 

[Towpack]

I've just been doing a valve clearance check/re-shim on the bike @ 24k miles and the the backs of the inlet valves look almost like new. Some discolouration but no build up of any deposits. Apart from regular maintenance and oil changes etc I think the reason for this is two fold. Modern bike engines run very lean and it's never used for short journeys or commuting etc. Always around 100 miles on a run with some 'enthusiastic' use of the throttle. JMO