courtgordon

I decided to take off my intake manifold and upper plenum this weekend to see how bad it was and to do a little port and polish work while i had everything off and pull my injectors and give them a clean. I have to say i was shocked how much sludge was built up in the entire intake system from throttle body clear into the head.

I started by unbolting the upper plenum from the throttle body and the lower intake manifold (2bolts 2nuts on TB and 2bolts 3nuts connecting to lower intake)



Then i was able to see the 1/16in. of sludge that was built up. as i took off the lower intake from the head (2bolts 3nuts again if i remember right)




So i started with some carb n choke cleaner and a wire brush which was only getting to what i could reach and wasnt really cutting it so i moved to pulling t-shirts soaked in carb cleaner through each chamber over and over for a couple hours it finally started to get better so i took a break from that and did some gasket matched porting with a diamond bit and a drill on all the chambers.. then back to pulling t-shirts again and again it kept improving but still wasnt what i wanted so i welded a couple 120grit sanding wheels to a long shank and did some polishing with a drill then i soaked both the plenum and lower intake in hot water and a cleaning agent overnight to loosen up anything that remained which worked really well and as you can see i got it prety dang clean after i ran a few more t-shirts through each port.






Now with the intake system ported and clean i removed the main cause of all this sludge build up which would be the EGR system and for those that dont know this basically takes exhaust and puts it right back into the beginning of your intake system just downstream from the throttle body poluting your suppose to be cold clean air with your motors waist (exhaust) so with this gone my intake should stay nice and perty clean and feed my motor with cool clean air.


Then make a couple caps to block off where the EGR tube took exhaust from exhaust manifold and where it put it in intake,

Cap put on exhaust manifold


Now with the EGR taken care of its on to fuel injectors and they werent quite as bad as expected but nonetheless could use a cleaning



So i filled some caps off of spray paint cans with good ol carb n choke cleaner and ill let the injectors soak overnight also sprayed some carb cleaner down the gas intake hole on the injector bar


Tomorow ill finish cleaning off the tips of the injectors and then re-install them along with the freshly ported and polished intake system.

courtgordon

Alright finished cleaning the fuel injectors


Then put on the other aluminum plate i made to block off where the EGR went into the plenum.



Then put everything back together starting with injectors


Then lower intake and plenum using all new gaskets


last thing i had to do was solder in a resistor to the temp sensor that goes right downstream from where the egr use to plug into the plenum at this is to trick the computer system and keep my check engine light off.


All put back together its the shiniest thing under my hood looks like i need to power was my engine.


Truck runs great i did notice a slight improvement in throttle response when first depressing the peddle like how it runs on really cold mornings which makes sense cuz now there is no hot exhaust being shoved into my intake along with a nice smooth clean shot for cool air to travel straight to the head. I would say its an inexpensive way to gain a little bit of power and mpg, obviously if you have to pass smog you couldnt romove the EGR.