Bore-ing and cleaning the intake manifold pt. 2

So, continuing from part 1, making the gasket for the intake manifold. You can use those normal gasket papers available from any car parts shop that sells it. Its quite cheap and it does the job quite well, less than rm10 can get you one BIG sheet of paper. making gaskets are very easy, just trace and cut. =) This is the end product.

Next day, fixing the whole car back together… Manifold and gasket goes in first,

Manifold is in, now connecting all the wires and plugs.

See how rusty my brakes are, haven’t driven the donkey for a few weeks already.

…. and it’s all done! Will be making a DIY oil catch tank to prevent the manifold from getting dirty so fast again.

Bore-ing and cleaning the intake manifold

So one night for no reason at all again, I went to check on my throttle body. I noticed it was kinda different from the normal throttle body sizes form google.

SO I TOOK IT OUT. >:D

and

It was 60mm, from the 4G92 mivec/ 4g63 Evo III engine… What a jolly delightful surprise. =)

Only problem was, the intake manifold hole was too small for it. (54mm)

Soooooo, it was time to take it out for some boring/cleaning. Be sure to label all the pipes and whatever nonsense you are removing, otherwise, when you fakap, you fakap bad like mad.

Letting out all the fuel in the fuel rail…Some of the petrol leaked out, this was all that i managed to catch.

Well, shouldnt put it to waste, right? =)

…And here is the car with the intake manifold taken out. Didnt take very long, about 2-3 hours to remove it, and this is the first time i am trying.

Parts all kept in my bedroom to prevent getting thrown away by my mom.

Next, boring the manifold. Since I didnt have a proper filing bit, I just used a grinder bit with a drill. This was a goddam slow and boring process. =/

But I managed to bore it. quite satisfied with the new size of the intake hole. 58/59mm, leaving it roughly 1mm smaller than the throttle body as i was afraid that i might overbore the manifold.

Now, for the cleaning process. T’was a good decision to remove the whole intake manifold as compared to just boring it on the car itself, as it was all… black.

I asked one random workshop how much it would cost if i sent it to them for cleaning,

RM40.

Nah, I’d rather do it myself. Bought thinner for about 18 bucks, and one of those brushes for toilet bowls for 2 bucks. Make sure the brush is not plastic cause most plastic reacts with thinner, and I doubt that melted plastic in my intake would be very fancy at all. Open up the brush and make it straight, from its bendy shape. Also, cut off a little portion of it and connect it to a wire. There you have your very own 2 pipe cleaners! ;D

I only used like 2/3 of the can of thinner to wash the intake, so for about 20 bucks, you can get it washed yourself, and still have like 1 liter of thinner left for your amusement. How cheap is that. So after cleaning, the manifold naturally will be dirty. I used some engine degreaser to wash it, available at pasar road for rm18 a gallon, will last you for a long long time. If you don’t wanna buy that though, you can still use thinner to wash the outside too. I had enough thinner on my hands for a day though.

See how clean it is now?!?!?!?!??!?! =D