Do-it-yourself intake manifold draft repair

In detail: do-it-yourself repair of the intake manifold thrust from a real master for the site my.housecope.com.

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Undoubtedly, the intake manifold is an extremely important part in the car design. It is not surprising that its malfunction can lead to extremely negative consequences. Therefore, it is important to know how you can quickly restore this part, and what malfunctions can occur with it.

Before proceeding to troubleshooting and repairing them, you need to understand why this part is needed and what functions it performs. So, this is one of the most important parts in an engine powered by the internal combustion of an air-fuel mass.

The role of this part is to distribute the air-fuel mass to the cylinders. The better the distribution, the better the performance of the motor. That is why the performance of this part is so important. If any malfunctions are observed with it, then this negatively affects fuel and oil consumption, as well as the dynamics of the car.

The intake manifold can act as a platform to house critical engine components such as the throttle valve or fuel fittings. In fact, a lot depends on the design features of a particular model.

Video (click to play).

As the pistons move downward, a partial vacuum occurs in the intake manifold. Simply put, the pressure drops below atmospheric pressure. Engineers make the most of this effect.

The vacuum in the hands of skilled designers and scientists has become a source of strength. She has become the main resource for the operation of such additional systems as:

Cruise control,
brake boosters,
emission control devices,
wipers,
crater ventilation, etc.

In fact, the list of systems that work due to the formation of a vacuum can be continued indefinitely.

The device consists of a closed reservoir. It has a complex shape, consisting of a common chamber and branch pipes. The number of the latter is determined by the number of cylinders.

Until 2000, intake manifolds were made of aluminum. But with the advent of the new century, manufacturers increasingly began to use composite. This is due to the higher performance of this material. Moreover, even plastic is used in production.

To understand how the intake carburetor works, you need to consider how the entire system works. From the carburetor, atomized fuel enters the chamber. To achieve the desired spray level, the channel surfaces are not sanded. The important thing here is not to cross the line. The fact is that too rough a surface causes increased turbulence, and this is highly undesirable.

The benchmark is the intake manifold designed specifically for racing cars. It has an ideal shape, which in turn served to transform it into a standard for every passenger car.

The part has a well-defined length, shape and capacity. These parameters are the result of many years of research. The intake valves of the motor are responsible for the direction of the air flows.

The intake manifold is a rather complex part, the design of which has a number of important details. In addition, it is still fragile. It is not surprising that malfunctions for this node are frequent.

Most often, experts in automotive services have to deal with failed dampers. At the same time, there is a significant loss of power. Also, the engine starts to consume more fuel. The thrust drops several times. Among the reasons for such a malfunction of the intake manifold are noted:

too high temperature inside the system,
the appearance of condensation,
poor quality of the material.

Another common intake manifold malfunction is a failed valve. This device controls the dampers, opening and closing them at the right time.

Quite often, when diagnosing the intake manifold, the following malfunction is detected: the tube peels off from the swirler. It can be quite easily diagnosed by the characteristic sound that appears every time you move. This is a kind of noise or crackling.

An intake manifold malfunction such as air leakage is very strongly reflected in engine power. By the way, in this case, noise will also be observed. But it will look more like blowing.

There is a special sensor to measure the pressure inside the intake manifold. It helps to optimize the formation of the air / fuel mixture. If the malfunction of the intake manifold is associated with it, then the ECU switches to emergency mode.

Important! In the worst case scenario, the engine will simply refuse to start.

Many drivers are afraid that oil will get into the intake manifold, and this will cause it to malfunction. We have to admit that such a possibility really exists. But there is a tried and true way to find out.

It's all about the expense. If you notice that your car has started to use more oils, this is at least reason to think. In the worst case scenario, consumption may exceed 1 liter per thousand. Of course, in this case, you need to think about repairs.

The process of repairing a malfunction of the intake manifold begins with its dismantling. In principle, this is not difficult. With the optimal location of the part, dismantling can be done in 10-15 minutes. The process itself consists of the following stages:

Find the fuel pump.

Remove the fuse and turn on the motor. This is necessary in order for the pressure to drop in the system. The engine will stall soon.

Disconnect the battery and remove the decorative cover that protects the motor.

Remove the pipes and remove the air filter.

Unscrew the throttle assembly. In this case, the fasteners on the damper must not be hooked.

After you complete this list of points, you can assume that half the distance has been passed, and soon the malfunction of the intake manifold will be corrected.When you have dismantled the intake manifold, it's time to start repairing it. There is one important clarification to be made here. Not all faults can be repaired. In some cases, the only option is to completely replace the part.

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So let's start with the simplest. If you notice such a malfunction as a pipe peeling with a square hole shape, then you need to drill two holes in the intake manifold.Through the holes you can get to the tube. After you drill the holes, you will need to fix the structure with self-tapping screws. In this case, you must understand that the valve and the intake manifold flap change together. As a result, if at least one part breaks down, the entire intake manifold must be replaced.Sometimes it is very difficult to determine exactly where the breakdown is. After all, usually signs can indicate several details. I don't really want to disassemble half of the car in order to dismantle, check, and then put the part back in place. Fortunately, there is a method that allows you to test a node without dismantling it.The pressure level in the intake manifold must be -80 kPa.If the machine has been in operation for a long time, an indicator in the region of -70 kPa is allowed. Take a vacuum gauge to measure pressure. When, when measuring, you notice certain jumps, then there is a problem in the intake manifold. Unfortunately, it can be not only in him. Pressure surges can indicate problems such as:To find out how well the exhaust gases pass, unscrew the oxygen sensor. You need to unscrew the one in front of the catalyst. Screw the adapter into the hole. Connect a pressure gauge to it. Indication for idle speed 10 kPa. With an increase in the number of revolutions to two and a half thousand, this figure should rise to 20.As you can see, you can check the intake manifold and find out if it has a malfunction without dismantling it. But for serious research, it is simply necessary. Since manipulations with a pressure gauge are not always accurate.The intake manifold is one of the most important parts of the car, which is notable for its complexity. Fortunately, its main malfunctions can be eliminated by hand. It is also possible to diagnose the device without first dismantling it. Although dismantling helps to find the malfunction with greater certainty.Why do we need to know how to remove an engine intake manifold? The answer lies in the numerous functions that this part performs, even if indirectly, and if it breaks down, we run the risk of experiencing very great discomfort. Let's take everything in order.The value of this element cannot be underestimated, because it is in it that the meeting of fuel and air occurs, as a result of which a combustible mixture of the desired consistency is obtained... He also controls the process in which it should be evenly distributed over all cylinders. And this is very important, since only then will the maximum performance of the car engine be achieved. So you cannot neglect procedures such as repairs, cleaning the intake manifold, and so on. Image - DIY intake manifold traction repair

In addition, some elements of the engine are mounted on it, for example, fuel injection equipment, a carburetor, and throttle valves. And the vacuum that forms in it is the source of the driving force for a number of systems (windshield wipers, cruise control, vacuum brake booster, etc.). And in case of failure of one of these systems, most likely, it will be necessary to remove the intake manifold. Let's consider its design.

Most often, this part is made of aluminum alloys or composite plastic materials and is attached to the cylinder head on the left side. A sensor on the intake manifold records the temperature and pressure, and the control unit, in turn, calculates the mass of air in it. And already based on these data, pulses are formed, through which the injectors are controlled. Thus, the preparation of a fuel-air mixture of a given composition takes place.

Inside this part there is a switch shaft and a vacuum element, to which the vacuum generated by the tandem pump is supplied through the flaps to the intake manifold. Each inlet is divided into a vortex and a filling section. The switching shaft, in turn, can only block the latter, at which point suction takes place through the first channel. So the flow rate in this channel is significantly increased.

This part has a rather complex design, which means that the likelihood of a particular breakdown increases significantly. Most often, dampers fail, especially this type of malfunction is relevant for Mercedes... In this case, the car significantly loses power, fuel consumption increases, traction and engine performance in general deteriorate. The manifold dampers fail for the following reasons: increased temperature, poor quality of the material from which they are made, and the appearance of oil condensation.The intake manifold flap control valve may also fail.

The main sign that oil has got into the intake manifold is its increased consumption, sometimes it even exceeds 1 liter per 1000 km.

In plastic parts, the tube may often detach from the swirler, which provokes the appearance of a characteristic sound during movement (crackling, noise). This breakdown can be completely eliminated on your own. In addition, air leaks can occur in the intake manifold. This malfunction will also affect the power, but in addition to this, there will also be noise that resembles blowing, or vice versa - suction.

In order to measure the absolute pressure in the intake manifold, there is a special sensor. He is also responsible for optimizing the formation and combustion of the air-fuel mixture. If it fails, then the ECU, most likely, will work in emergency mode, and sometimes the engine may not start at all. Despite the fact that a modern intake manifold pressure sensor is a rather reliable device, nevertheless, malfunctions in it are possible.

Basically, to repair or replace a part, you need to know how to dismantle the intake manifold. In principle, this task is not difficult, and you can cope with it in literally 10 minutes. We find the fuel pump and remove the fuse from it, and then start the engine. So the pressure in the system will drop, gradually the engine will stall. After that, you can turn off the battery and remove the decorative cover from the motor. Now you need to remove the pipes from the air filter and remove it. Then you should unscrew the throttle assembly, but without touching the damper fasteners. Now you got to the collector.

Further, in case of detachment of the square tube, it is necessary to drill two holes in the collector (the drill diameter is taken 4 mm) so that through them it is possible to get to this tube. Then we screw the screws into these holes, fixing it. The dampers and control valve cannot be changed separately or repaired, so you have to buy and install a whole new part. If the cause of the breakdown is found in the sensor, then the failed element needs to be replaced.

Why do we need to know how to remove an engine intake manifold? The answer lies in the numerous functions that this part performs, even if indirectly, and if it breaks down, we run the risk of experiencing very great discomfort. Let's take everything in order.

The value of this element cannot be underestimated, because it is in it that the meeting of fuel and air occurs, as a result of which a combustible mixture of the desired consistency is obtained... He also controls the process in which it should be evenly distributed over all cylinders. And this is very important, since only then will the maximum performance of the car engine be achieved. So you cannot neglect procedures such as repairs, cleaning the intake manifold, and so on.

Most often, this part is made of aluminum alloys or composite plastic materials and is attached to the cylinder head on the left side. A sensor on the intake manifold records the temperature and pressure, and the control unit, in turn, calculates the mass of air in it. And already based on these data, pulses are formed, through which the injectors are controlled.Thus, the preparation of a fuel-air mixture of a given composition takes place.

This part has a rather complex design, which means that the likelihood of a particular breakdown increases significantly. Most often, dampers fail, especially this type of malfunction is relevant for Mercedes... In this case, the car significantly loses power, fuel consumption increases, traction and engine performance in general deteriorate. The manifold dampers fail for the following reasons: increased temperature, poor quality of the material from which they are made, and the appearance of oil condensation. The intake manifold flap control valve may also fail.

The main sign that oil has got into the intake manifold is its increased consumption, sometimes it even exceeds 1 liter per 1000 km.

Read also: DIY Renault repair

The design of a specific collector and the possibility of replacing gaskets or renewing the sealant can always be seen on the diagrams, which, for example, are in the spare parts catalogs on the website of well-known online stores.

Medical history: how to check the condition of the engine inexpensively

As a rule, the joints of plastic elements are more capricious. If the collector is collapsible, then its tightness is easy to restore. True, in most cases the unit has to be removed from the motor. And in the case of a "monolithic" collector, you will have to think about how to seal it.

The safest option is plastic welding. This is a technology by which, for example, cracks and breaks in bumpers are repaired. However, this option can be expensive when it comes to large recovery areas. In this case, it is sometimes cheaper to buy a new or used collector. If you do this on your own, you will have to spend money on expensive equipment: a special construction hair dryer and a dremmel.

A simpler option is to arm yourself with a soldering iron and solder a plastic seam to the joint. For this, for example, pieces from a plastic measuring bucket for liquids are suitable. Here, by and large, only patience is needed.

The quickest and easiest way is to cover the joints with a sealant. True, this method is the least preferred for supercharged engines. Their intake air pressure in some operating modes is significantly higher than that of atmospheric engines. Therefore, any sealants can give slack, and soldering is more suitable for a supercharged engine.

Armed with the theory, we will repair the collector at the editorial Kalina. The composite plastic path of the 1.6 (106 hp) naturally aspirated gasoline engine leaks along the perimeter of the wells for the ignition coils. Apparently, these are the consequences of frequent tests on the Smolenskoye Koltso race track, in which the car and especially its engine were exploited to the limit of their capabilities.

Intake manifold Copious fogging of the collector along the joints in the area of the wells of the ignition coils; Abundant fogging of the collector along the joints in the area of the wells of the ignition coils.

The new collector costs about 7,000 rubles in online stores. Such a high price tag for a unit for a domestic car is associated with its design features. It has built-in dampers of a variable channel length system. And the collector of the 127th motor itself is more voluminous and massive in comparison, for example, with the collector for the 126th Priora engine. Buying a new node is not our method.

Alas, the study of the schemes upset. This manifold is non-separable. The experiment with violent halving seemed too dangerous due to the presence of the shutters. In addition, for this, it would be necessary to remove the collector, and on the 127th engine it is quite laborious. Therefore, it is easier to get off with a local repair.

Intake manifold Oil extrusion section Oil extrusion section Intake manifold After local cleaning, it became clear why these places are the most "snotty" - an indecently large gap. After local cleaning, it became clear why these places are the most "snotty" - an indecently large gap.

Due to the large area of joints requiring sealing, the option with plastic welding is swept aside by the rhinestone - it is too expensive. You can be puzzled by self-sealing the cracks with a soldering iron. But, since we have a low-volume atmospheric engine, it is quite enough to walk with a sealant along the joints.

Before carrying out work, we check whether air is sucking in problem areas. As it turned out, the gaps were so large that spraying the brake cleaner made the engine convulse!

silicone sealant Universal silicone sealant. Most of these tubes are equipped with a convenient nozzle. By cutting off a part of the spout, you can select the desired hole diameter so that the sealant fits well into the joints. Universal silicone sealant. Most of these tubes are equipped with a convenient nozzle. By cutting off a part of the spout, you can select the desired hole diameter so that the sealant fits well into the joints. Intake manifold It turned out not very aesthetically pleasing. It's good that these places are not in sight. It turned out not very aesthetically pleasing. It's good that these places are not in sight.

The restoration work took about an hour. For good access to repair sites, it was necessary to remove the individual ignition coils. A sealant and a bottle of cleaner cost 300 rubles. The repeated test for air leakage after drying of the seal was successful - the revolutions stopped floating!

We restore the intake manifold tightness on our own
A source

An article on how to properly repair and clean the intake manifold of a car engine. Tips and tricks. At the end of the article - an interesting video about the intake manifold of a car.

The content of the article:

Design features
Intake Manifold Engineering Development Process
Possible breakdowns
Intake manifold repair
Cleaning
Collector video

In order for a car engine to work flawlessly, it is necessary that all the components and assemblies are in perfect working order - from the valves to the intake manifold. Especially important is the condition of the intake manifold, which mixes fuel with air in the right proportions.

In fact, the intake manifold is a rather complex device that works in this way: fuel and air penetrate into the system, and there the resulting mixture is divided into several streams, the number of which depends on the number of cylinders.

As a result of operation, the pistons of the cylinders discharge the capacity to a state close to vacuum, which neutralizes the gases from the crankcase that enter the manifold through the ventilation lines.These gases are mixed with gasoline vapors, and the resulting mixture is then ignited. This design makes it possible to significantly reduce toxic emissions into the environment.

Starting from the origins of car production, the intake system has undergone multiple upgrades and eventually turned into a device that now contains the following elements:

frame;
pipe branch;
throttle valve;
air gripper;
muffler;
collector;
pad.

As can be seen from the list, the collector is only a fragment of the entire complex system that ensures the reliable operation of the motor vehicle. Therefore, in no case should you underestimate its role.

The manifold is attached to the left of the cylinder head. It has sensors that monitor pressure and temperature. The control electronics processes the information and generates the necessary commands.

Until a certain point, the collector was made of three types of material:

iron;
cast iron;
aluminum.

I must say that all three types of designs had their flaws. For example, cast iron is a fairly strong material, but at the same time, by its weight, it increases the mass of a car.

The fact is that due to the heating of the collector, the air temperature rises. Expanding, it penetrates the cylinders in a discharged form and, accordingly, in small quantities. And the lack of air in the cylinders, as you know, is fraught with large excessive consumption of fuel.

As a result of this "chain reaction", the overall performance of the engine is reduced. That is why experienced motorists attach particular importance to the serviceability of the intake manifold and try to clean it in a timely manner and, if necessary, repair it.

Some breakthrough in the design of the intake manifold occurred at the end of the last century, when developers began to use composite materials. These materials are based on plastic.

This discovery made it possible to significantly increase the operational life of the device, in particular, providing the functionality of the intake manifold with the following beneficial effects:

significant decrease in thermal conductivity;
increased saturation of the cylinders with air;
increase in engine power.

However, the most important result of the scientists' activity was the thermal stability of the new type of intake manifold - it began to heat up much less.

As already mentioned, the intake manifold is considered a rather complex device, therefore, breakdowns in this system are not uncommon. Most often, the most sensitive parts fail.

A large percentage of breakdowns occur in the intake manifold flaps. And this is quite natural, because it is they who take on the maximum load. Due to this breakdown, the engine starts to work intermittently, traction weakens, fuel overconsumption appears, and the machine's power is noticeably reduced.

As we have already said, composite materials are used for the production of the collector. Therefore, some elements are made of plastic. For this reason, the tubes sometimes extend or separate from the swirler altogether. This breakdown can be identified by its characteristic crackling sound while driving.

Intake manifold leakage is also a common problem. This breakdown negatively affects the dynamic performance of the vehicle.

The biggest nuisance is when the absolute pressure sensor breaks down. In the presence of this malfunction, you simply cannot start the engine. However, if the control unit is in good working order, it will be able to react to this breakdown in a timely manner, and then the system will go into emergency mode.

To repair the intake manifold, it must first be dismantled. Yes, sometimes you can leave it in place, for example, if you seal the air leak with sealant.But in case of serious malfunctions, the collector will have to be removed.

Removing and then pulling out the intake manifold will not be difficult and time-consuming if you do everything right. The first step is to locate the fuel pump. Then you need to remove the fuse. Then start the engine.

The engine is started to reduce the pressure in the system. After starting, the motor will quickly stall, and this will mean that the goal has been achieved. After that, do the work according to the following algorithm:

remove the cover from the engine;
separate the pipes from the air filter;
remove the filter;
remove the throttle assembly. At the same time, try not to touch the flap mountings, otherwise they may be damaged.

After completing the specified list of works, you will be able to see the collector. Pay attention to the square tubes. In case of delamination, you will need to drill two holes in the manifold and then fix the tube with self-tapping screws.

Be sure to revise the sensor. If it turns out to be damaged, it will not be difficult to replace it with another one. The sensor is installed so easily that it will not take a long time to remove and mount it.

If, while the engine is running, you suddenly hear a knock from the manifold, then do not even doubt that the device is clogged and needs to be cleaned. To clean the collector properly, follow these steps:

install the car on the lift;
unscrew the screw that secures the manifold to the frame;
remove the throttle valve;
remove sensors and tubes;
unscrew the bolts securing the manifold to the motor;
start disassembling the device. The collector is assembled from two halves, so you need to unscrew the bolts that tighten these parts, and then disconnect;
put the disassembled collector in a container with a solution of white spirit and then brush the dirt from its surface with a brush;
before starting the assembly of the device, it is necessary to coat all the parts that are connected into a single communication with a sealant.

That, in principle, is all, the collector is cleaned. Now try to set everything up in reverse order. When reassembling, remember to clean the throttle valve, change the gaskets and reinstall all sensors.

Remember that the intake manifold is one of the most important devices in a car. Therefore, keep an eye on it, and, if necessary, clean or repair it, since neither one nor the other presents any difficulty. You just need to do everything that is specified in the instructions, and the engine of your car will start working again at any speed. Good luck and safe road!

An interesting video about the intake manifold:

Video (click to play).