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Thread: DIY: EGR and Intake Manifold Cleaning Reply to Thread
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  Topic Review (Newest First)
07-19-12 02:38 PM
How to keep EGR and intake clean???

Now that EGR and intake cleaned, $850.00.

How do you prevent from happening again????

I use 93 octane and once in a while intake and fuel additive, not too ofthen though.

I can't find anything online on how to prevent.


06-30-12 05:34 PM
Try this first

I just finished following this walkthrough and I would recommend doing what JPillans says, as well as running seafoam through it. When I opened up my manifold, the main part looked pretty clean, i assume from the seafoam. However, the aft plate area was completely clogged because there is a ridge that looks like it blocked the seafoam from getting back to the EGR area of the manifold. I could have saved alot of time and some money on gaskets if I just laid on top of the engine and drilled out the carbon from the back. I think the end result (combined with Seafoam) would have been pretty similar to taking the whole thing off.

Here is my before and after pics of the aft egr area

Originally Posted by JPILLANS View Post
Here in the Dallas area we see a lot of egr ports clogged. I would say we do at least 4-5 port cleanouts a week. The 96-97 rl's have a warr. extension that will cover this at no charge up till 150k . Other year models are out of warr. @50k miles.

The cleanout can be done without any parts needed, the intake does not need to be removed. Our techs just lay on top of the engine and reach between the fire wall and the back of the cyl. head to access the egr pipe and port plate. Remove the 4 crossover tube nuts and crossover tube. Then remove the port plate bolts and plate. Then start with a 1/4 inch drill bit in your hand and push the drill bit through the built up carbon in the back of the cyl. head until you break through to the open chamber on the inside of the head. Keep increasing the size of the bits until you have cleaned the round hole completely. You will just twist the bits to "hand drill"
through the carbon. This is tedious work and is why it cost so much. But it is not that bad. Once you have it all back together, you'll need the code cleared from your system by a code scanner available just about anywhere that sells tools
12-24-11 01:14 AM

i need help short on time and i have clean the egr , egr block, pipe and now im stuck and can not get the plate off of the intake. i can see it has build up and is probably why my egr cel is on. is there a trick on easy way to get the plate off. i have the screws off but it will not budge. i have e check due tomorrow and wanted to get it cleared. i would hate to have to put it all back together and still not solve the problem when im right there. can someone give me some insight on how to get the plate off. i thought of using some PB blaster but dont want to mess the gasket it up if i can not get it off. i have replacement gasket but wont do any good if i cant get it off.. please help.

thank you for any help with this. it is greatly appreciated.
05-30-11 06:59 PM
Thank you!

For your help! This has been so helpful and I was able to pass inspection too!
04-26-11 08:34 PM
alohamonte should you also clean the injectors and repalce the orings while youre at it. if the intake is junked up the injectors are probably just as clogged.
10-28-10 02:20 PM
huntertn I cleaned mine about 30,000 miles ago without pulling the intake. Just removed the pipe and egr plate from the back of the engine. Used the technique previously described in this post. A mirror propped up against the firewall helps too. I figured I would try doing it this way and see how long it lasts (been about a year so far). It only took me about three hours total and the next time it will go a lot faster (probably 2 hours).

My pipe was pretty clean but the area under the plate was pretty clogged.

09-27-10 12:36 AM
Japam well it's back again. Need to check if it is the same code. If it is then for sure I'm going to have to do the manifold cleaning.
09-16-10 03:14 PM
Originally Posted by samlbc View Post
dude you know that stuff is flammable right?
well I let it sit for a while to break down all the carbon. Worked for me
09-16-10 01:50 PM
Originally Posted by Japam View Post
Cleared the "insufficient flow" code by spraying a bunch of carb cleaner into egr valve and down the egr pipe. After doing that, it bogged a lot and died a few times when I started it and the code came back on. Once it started idling normally, I reset the computer by disconnecting the batter for a few mins and reconnecting it. The CEL has been off for almost a week now.
dude you know that stuff is flammable right?
09-15-10 03:16 AM
Japam Cleared the "insufficient flow" code by spraying a bunch of carb cleaner into egr valve and down the egr pipe. After doing that, it bogged a lot and died a few times when I started it and the code came back on. Once it started idling normally, I reset the computer by disconnecting the batter for a few mins and reconnecting it. The CEL has been off for almost a week now.
06-07-10 02:26 PM
turbobore I recently took my '02 to my mechanic who removed the manifold and cleaned all of the egr ports. He charged $600 and the local dealer wanted $750. I don't have time for jobs this time consuming otherwise I'd do it.
05-17-10 07:28 PM
Originally Posted by anguyen89 View Post
my check engine light came on a couple days ago it was a P0401 code... it sounds like this is what i need to do to fix it but before i do i wonder if sea-foam would work for a less extreme alternative?? any success stories with it? cause taking apart the manifold is if i dont have any other choice, any input?
hey i have a 99RL and seafoam helped alot. I have a better gas mileage than before. I recommend the sea foam treatment. Still i also recommend you clean the EGR valve and pipe
01-07-10 09:00 AM
vitagreg Can someone guide me to the parts in question? Should I remove the cross brace, the engine cover to access the pipe, plate and hole in manifold?
09-26-09 01:51 PM
legendLS I have a 96 RL that's been plagued with the P0401 problem for years but I'd been put if off until now. After taking the manifold apart I see why seafoaming it doesn't help much as the carbon deposit behind the EGR cover in the manifold is too tough to be dissolved by seafoam. I have to use some force and carbon cleaner to remove all deposit. I guess seafoam would help prevent the buildup. Once the build-up is significant, seafoam isn't as helpful. I'm still waiting for the gaskets to arrive to put everything back. Here are the gaskets with their OEM part numbers

R intake manifold gasket: 17105-P5G-004
L intake manifold gasket: 17106-P5G-004
Bypass valve gasket: 17115-P5G-003
Intake manifold chamber gasket: 17121-P5A-004
Throttle body base gasket: 17175-P5A-004
Throttle body gasket: 16176-P5A-004
EGR cover gasket: 17123-P5A-004
EGR pipe gasket x 2: 18721-PR7-A01
EGR valve gasket: 18715-PB2-000

That's all.
07-31-09 09:08 PM
Originally Posted by mr marcus View Post
could somebody post the gaskets that are needed? and how much they cost and where to order? i took my rl to a bodyshop and they said is going to be about $250 for the gaskets plus labor. so that totals to about what the dealer will charge
I need this too! Please Help
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