A PDF guide to cleaning carbon from ML manifolds

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A PDF guide to cleaning carbon from ML manifolds

Postby Cowboy Dave on Sun Feb 24, 2013 2:41 pm

Some time ago, (too long ago if I'm honest about it) a clever guy by the name of Era2003 posted an epic post about his efforts to remove and clean his manifolds. The original post is here: http://www.newtriton.net/phpbb/viewtopic.php?f=39&t=2477&p=294953&hilit=era2003#p294953

We asked him whether we might be able to turn his posts into a PDF guide along the lines of Fraz's guide to CV removal and replacement. He was about to shoot off on holidays but very kindly provided me with a word document with all of the text and photos. Tex then did some work on it (thanks bloke :D ) and I've finally finished my editorial contribution today.

Era last visited the forum on December 5, 2012 so he may not be around for a while to see this. That aside, he deserves a massive thanks for the effort he put in.

Any errors people find are probably mine introduced during the editing phase - feel free to point them out and if necessary I will edit the original and replace the PDF with an improved version.

If anyone has part numbers for gaskets for example or torque settings that are supposed to be used by all means contribute those just so we can refine the document further. Similarly if someone has found a good solvent or cleaning method that is safer than using petrol for cleaning the carbon off that might be good to include.

Also, if someone wants to write one for the MN - please do.

So without further ado - here is a PDF version of the guide to cleaning carbon from ML manifolds:

carbon removal reduced size.pdf
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Shrek on Thu Mar 07, 2013 6:12 pm

Does this help with torque settings ?

STANDARD PART/TIGHTENING-TORQUE TABLE
M1001001100715
Each torque value in the table is a standard value for tightening under the following conditions.
1.Bolts, nuts and washers are all made of steel and plated with zinc.
2.The threads and bearing surface of bolts and nuts are all in dry condition.
The values in the table are not applicable:
1.If toothed washers are inserted.
2.If plastic parts are fastened.
3.If bolts are tightened to plastic or die-cast inserted nuts.
4.If self-tapping screws or self-locking nuts are used.

STANDARD BOLT AND NUT TIGHTENING TORQUE Thread size Torque N⋅m
Bolt nominal diameter (mm) Pitch (mm) Head mark "4" Head mark "7" Head mark "8"
M5 0.8 2.5 ± 0.5 5.0 ± 1.0 6.0 ± 1.0
M6 1.0 5.0 ± 1.0 8.5 ± 1.5 10 ± 2
M8 1.25 11 ± 2 20 ± 4 24 ± 4
M10 1.25 23 ± 4 42 ± 8 53 ± 7
M12 1.25 42 ± 8 80 ± 10 93 ± 12
M14 1.5 70 ± 10 130 ± 20 150 ± 20
M16 1.5 105 ± 15 195 ± 25 230 ± 30
M18 1.5 150 ± 20 290 ± 40 335 ± 45
M20 1.5 210 ± 30 400 ± 60 465 ± 65
M22 1.5 290 ± 40 540 ± 80 630 ± 90
M24 1.5 375 ± 55 705 ± 105 820 ± 120


FLANGE BOLT AND NUT TIGHTENING TORQUE Thread size Torque N⋅m
Bolt nominal diameter (mm) Pitch (mm) Head mark "4" Head mark "7" Head mark "8"
M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2
M8 1.25 13 ± 2 24 ± 4 28 ± 5
M10 1.25 26 ± 5 50 ± 5 58 ± 7
M10 1.5 25 ± 4 46 ± 8 55 ± 5
M12 1.25 47 ± 9 93 ± 12 105 ± 15
M12 1.75 43 ± 8 83 ± 12 98 ± 12

Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
•Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the bolt strength.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby RHKTriton on Thu Mar 07, 2013 10:21 pm

An excellent write up.

Also shows what a shit design the induction plumbing is.

The Peugeot and Vito I had had plastic inlets with long inlet pipes, which promote good flow and better torque.

Be great if there was an aftermarket inlet manifold.
Don't let the b'strds get you down!!
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Shrek on Tue Mar 12, 2013 6:11 pm

this might be easier to read

Click to view larger picture
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby awill4x4 on Tue Mar 12, 2013 9:13 pm

I just thought I would ask.
Would it be ok if I copied the PDF and posted it on the Pajero forum?
I did try to post a link so the members there could see the procedure but you have to be registered here and seeing as we Pajero owners are suffering exactly the same problems with the 3.2 engines I thought it would be a useful guide on how to remove and clean the inlet manifolds.
Regards Andrew.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Cowboy Dave on Tue Mar 12, 2013 9:50 pm

I reckon I can live with that if you credit the original guy that wrote the material and took the pics and indicate where you got it from - even if the link doesn't work for non-members we might pick up a few new blokes out of it which can't be a bad thing.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby awill4x4 on Wed Mar 13, 2013 4:37 pm

Cowboy Dave wrote:I reckon I can live with that if you credit the original guy that wrote the material and took the pics and indicate where you got it from - even if the link doesn't work for non-members we might pick up a few new blokes out of it which can't be a bad thing.


Thank you Dave, that's much appreciated.
I'll be sure to credit the post to Era2003 as the original contributor and to provide a link to the NewTriton forum.
As a Paj owner I've learnt much from you guys here regarding the 4m41 engines and associated problems.
We have some issues peculiar to certain model Pajero's particularly regarding Diesel Particulate Filters which you Triton drivers are very lucky not to have attached to your vehicles. (as far as I'm aware)
Cheers Andrew.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Shrek on Fri May 31, 2013 5:09 pm

Hi Guys

First off... this guide is god sent

i have done 2 manifold cleans over the past month ( a mates and mine ) and the guide was great
I got it down to 5hrs.. but i had a replacement clean manifold to go on

Im not sure if i have problem with mine or not now... might be normal ??

Since the clean i have had a few strange things happening

My boost gauge is now erratic at idle & at a constant boost ( shakes ) and seems to be violent when boosting and backing off...

It also is now going to a negative boost of - 4

If i maintain it at 2000 rpm ( no load ) the boost keeps dropping in and out ( violently )... which i never noticed before

Ive checked all the connections and bolts twice and all seems well

I have the EGR blocked, DP chip, Manual boost controller set at 17psi

Any ideas ?

Shrek
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Shwa on Thu Jul 25, 2013 4:48 am

Also, if someone wants to write one for the MN - please do.

I've just purchased this service and repair manual for the MN from ebay http://www.ebay.com.au/sch/i.html?_trksid=p2047675.m570.l1313.TR0.TRC0.XMITSUBISHI+TRITON+2007+-+2012+%3A+Workshop+Service+%26+Repair+Manual+-+Interactive&_nkw=MITSUBISHI+TRITON+2007+-+2012+%3A+Workshop+Service+%26+Repair+Manual+-+Interactive&_sacat=0&_from=R40. If it's any good I'll see if I can work out a way to share it or link it on the Forum.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby oztri on Mon Nov 11, 2013 11:03 am

Hey guys,

Going to be giving this a crack next week. Anyone done this recently to their 3.2? Any last pointers?
How did you go shrek, with your boost issues afterwards?

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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Shrek on Mon Nov 11, 2013 11:14 am

If done it 3 times now, my car and 2 others... Got it down to 5 hrs start to finish

The instructions are exerlent , make sure you do the front nut up first on the manifold

Have a magnet tool handy for when you drop something

You'll love the result

Shrek
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby oztri on Mon Nov 11, 2013 8:21 pm

Hey Shrek, cheers mate. Magnet tool definitely a good idea, without a doubt ill drop some thing, other than the occasional curse :lol:

Did you use a torque wrench when whacking it all back together?
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Shrek on Tue Nov 12, 2013 5:16 pm

you will need it... its not if i drop it, its when i drop it

my experience is that it always falls behind the starter motor

Take your time, read the instructions ( great instructions ) and get ready to get dirty

Make sure the vacuum hose go on correctly... this was my problem

The results will amaze you...

Shrek
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Era2003 on Wed Nov 27, 2013 11:29 pm

Hi all,
Been away for a huge period of time both overseas and around the country. Sold the ML but now have a new 2013 glxr replacement( got it about 3 weeks go when I got back to Perth). Going to fit a catch can immediately seeing she's brand new.
Dave, Tex, excellent job on the PDF. You guys did a great job.
I'll be on the forum regularly. Great to be back.

Cheers
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Cowboy Dave on Wed Nov 27, 2013 11:55 pm

Couldn't have done it without you mate, good to see you back.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby 3084me on Thu Feb 20, 2014 8:54 pm

Good job on this sure made the job alot easier not having to bumble thru, For cleaning after scraping the worst of the crud off I used heavy duty engine cleaner from Supercheap about 4l of it. and a kitchen scrubbing brush& green scouring pad easy without scratching everything
1 question how tight do the Spring loaded manifold to head bolts be done upto? anyone know I can't find a torque figure anywhere so far.
Again thanks for posting this guide
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Cowboy Dave on Thu Feb 20, 2014 9:28 pm

There is a post with torque figures - I think. Give me a minute...


Err actually I was thinking of the one up there ^^^ not far below the PDF link...
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby 3084me on Thu Feb 20, 2014 9:49 pm

Cowboy Dave wrote:There is a post with torque figures - I think. Give me a minute...


Err actually I was thinking of the one up there ^^^ not far below the PDF link...


Yeah thanks I have that and the engine manual pdf, Has everything BUT intake manifold spring loaded nuts, if done to tight then obviously the springs wont be doing much, between removing, cleaning and refitting I had lost the recall of how tight thought it would be somewhere for such an uncommon system? have been trawling the interweb for hours....
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Cowboy Dave on Thu Feb 20, 2014 10:37 pm

I have the whole workshop manual somewhere but I've just done a fresh windows install and all my crap is everywhere unfortunately or I'd try and search it out for you. If you're stuck my suggestion would be that you look up a user called lee-thal and send him a PM. He'll have a bloke he can ask and he's bloody helpful like that. Just blame me for putting you onto him, he's probably used to it by now. Otherwise if you wait til the weekend I reckon someone will chime in with the answer for you.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby 3084me on Fri Feb 21, 2014 4:43 am

Cowboy Dave wrote:I have the whole workshop manual somewhere but I've just done a fresh windows install and all my crap is everywhere unfortunately or I'd try and search it out for you. If you're stuck my suggestion would be that you look up a user called lee-thal and send him a PM. He'll have a bloke he can ask and he's bloody helpful like that. Just blame me for putting you onto him, he's probably used to it by now. Otherwise if you wait til the weekend I reckon someone will chime in with the answer for you.


Good one thanks, seems there's lots of helpful guys on here sharing their tips tricks and great ideas about :)
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby evlids on Fri Feb 21, 2014 5:52 am

Just read through the pdf and it looks easy enough.

A quick note for anyone planning to do this install,

BE VERY VERY CAREFUL WHEN UNDOING INJECTOR LINES ON A COMMON RAIL DIESEL!!!!!!!!!!!!!!
There are MANY MANY cases where trained mechanics have cracked injector lines on common rails to discover there was still pressure in the rail. At full pressure the diesel can spray hard enough to get through your skin, and diesel in the bloodstream = death.

Don't want to deter anyone from this but every manufacturer I've worked for has made us sit through multiple training sessions on this. Personally I think it'd be pretty hard to mess up but it's worth mentioning.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby JakeMN on Mon Jun 16, 2014 9:14 am

Hi guys,

I cleaned out the inlet manifold on my 2.5 MN a week or two ago. I did have a search on this forum for a guide to get an idea how it would differ to the 3.2 ML however I didn't find anything, (I may have missed it however as I'm still getting used to the search function).

If there is indeed nothing, I'm more than happy to upload some photos and basic instructions of how to do this on the 2.5 MN engine.

Just trying to give back to the forum after all the useful information I have been able to score for free.
Regards,
Jake.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Cowboy Dave on Mon Jun 16, 2014 3:10 pm

That would be awesome mate, it has needed doing for a long time. If you PM me your email address I could send you the ml version in word format which might make it a bit easier to get stuck into? Some of it may be the same but if it's a standalone PDF then people can just print the one thing and take it out to the garage or whatever. Also happy to do the final edit/formatting for you as with the last one. If you're feeling inspired have a look at the rear brake guide as well for ideas on how to put it together.
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby JakeMN on Tue Jun 17, 2014 10:02 am

Thanks Cowboy Dave, I've already put a couple of things together in a Word document so no need to send it, I'll attempt to keep it in a similar format though and I'll send it through to you once compiled to be checked over.

Also, I'm not a mechanic so obviously there will most likely be better/safer ways to do things so any suggestions from other users who read the guide are more than welcome.
Regards,
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Re: A PDF guide to cleaning carbon from ML manifolds

Postby Cowboy Dave on Tue Jun 17, 2014 12:40 pm

8-) 8-)
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