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Thread: Manifold full of **** 2.2DTi

  1. #1
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    Vehicle : Vectra

    Trim : Design

    Engine : 1.9CDTi

    Year : 2005

    Mileage : Lots

    Default Manifold full of **** 2.2DTi

    Hi,

    Been having a poke around the car because there was no way it felt like 120 something HP. Took off the pipe from the intercooler to the throttle body so I could remove it and get to the boost sensor and discovered the intake manifold is just full of crap. A good centimetre thick in places. No wonder she couldn't breathe properly. Now running my fingers round the edge of the manifold, it feels like there's a seam there and it splits into a top and bottom half. Is this correct? I don't want to start undoing things and finding out it's pointless.

    Engine has done just shy of 140k miles. 140k miles of crap in the manifold it seems.

  2. #2
    Full Member bobssignum's Avatar
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    polishing something or other somewhere
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    Vehicle : Signum 2.0 DTi

    Trim : Elegance/Elite

    Engine : 2.0DTi

    Year : 2003

    Mileage : 73350

    Default

    Yes m8 the manifold at this point has two inlets one to the main part of the manifold and the other to the egr i have enclosed some pics just to give you an idea of what they look like cleaned up .
    0n a 2.2 you dont have the tps sensor fitted no real problems steming from there so just spray some carb cleaner into the manifold and let it soak for a bit then clear it out .
    Best remove boost sensor first and clean that seperately also with just a blast of carb cleaner and do the egr also with c c making sure the piston can move freely.
    Driving vauxhall,s for 30 + years
    and still loving it

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    Vehicle : Vectra

    Trim : Design

    Engine : 1.9CDTi

    Year : 2005

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    Default

    Cheers that's a great help. I had a fight with it using carb cleaner but wasn't getting too far so the throttle body is sitting in a bucket of petrol outside. I have yet to do the EGR, Not looking forward to that! You see in your first picture the bolts that are next to the hole on the top, there's 3 in the picture. One on the lower side and two on top, if these are removed and the fuel pipes bent back, can the top half be taken out?

    I'll go grab a photo in a sec, my manifold appears to be somewhat worse than yours!

  4. #4
    Full Member bobssignum's Avatar
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    Vehicle : Signum 2.0 DTi

    Trim : Elegance/Elite

    Engine : 2.0DTi

    Year : 2003

    Mileage : 73350

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    Yes there is nothing stopping you removing the lower throttle body cover but do not attempt to bend back the fuel pipes , they will almost certainly break its best to remove them by undoing the connectors at each end .
    Also after replacing the fuel pipes remember that you have to bleed the fuel system of air .this is not a job that i would take on if you are not sure of the layout .
    Also remember to all these parts there is gaskets between each face.
    The egr is relatively straight forward with only the two retaining bolts, two coolant hoses and the electrical connection to remove , only tip to this is have something handy to stem the coolant pooring out the hoses when removed
    Also when cleaning the egr also clean out the port that the cylinder part of the egr sits in
    Last edited by bobssignum; 8th October 2010 at 16:39.
    Driving vauxhall,s for 30 + years
    and still loving it

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