Hi everyone and a happy new year. I'm hoping to remove my inlet manifold when the weather gets kinder. Reason being, when I had my EGR swapped out for a clean one (had a spare one in my garage) there was a noticeable amount of gunge/deposits visible in there. My mechanic advised me not to pick at it in situ, but remove it and clean it out the safe way. I'm wondering if there will be any cast marks inside the manifold and if so, would it be worthwhile removing them with an appropriate tool/flapper wheel ?

Thanks in advance .

You'll find the inside of the casting reasonably smooth from a casting mark perspective. You can open the gasket mounting face up to the gasket line with a suitable tool if you really fancy some work to do. Easy enough to do even with basic hand tools.

 

If you are going to do that though, i'd advise doing it before cleaning the manifold out, as at least that way you'll get all the filings and swarf out at the same time as the gunk / crud then.

32 minutes ago, Lofty said:

You'll find the inside of the casting reasonably smooth from a casting mark perspective. You can open the gasket mounting face up to the gasket line with a suitable tool if you really fancy some work to do. Easy enough to do even with basic hand tools.

 

If you are going to do that though, i'd advise doing it before cleaning the manifold out, as at least that way you'll get all the filings and swarf out at the same time as the gunk / crud then.

Thanks lofty. I reckon I'll do that. Would a burr be suitable or too aggressive. Have you ever done this before ?

3 minutes ago, valvedoctor46 said:

Thanks lofty. I reckon I'll do that. Would a burr be suitable or too aggressive. Have you ever done this before ?

 

Yes I've done it on the build of my yellow vRS's engine, some pics on my thread somewhere. I used a dremmel with the smallest of flap wheels in and a half moon file. Easy job tbh.

11 minutes ago, Lofty said:

 

Yes I've done it on the build of my yellow vRS's engine, some pics on my thread somewhere. I used a dremmel with the smallest of flap wheels in and a half moon file. Easy job tbh.

Excellent stuff. I have all the tools you mentioned so will be having a bash ( when the weather gets better ) One last thing Lofty, I take it I will need to fit a new gasket when refitting the manifold ?

I'd always advise a new gasket, they're not too expensive. Not worth reusing gaskets.

15 minutes ago, Lofty said:

I'd always advise a new gasket, they're not too expensive. Not worth reusing gaskets.

Thanks mate 

No real point from a power perspective in opening up the manifold at the head end. Machining the EGR casting might have an effect on keeping it cleaner but not going to have much effect on power. To keep it cleaner, fit a catch tank, bigger the better, filled with proper steel wool or dish cleaners. You could elephant mod it but that's disastrous from an emissions POV.

I have a clean and enamel coated inlet manifold ready to go if your interested?.