MK2 1.6 TDCI Inlet Manifold Removal and Cleaning

[Sack13]

Greetings all.

I'm going to be doing my first ever (non stealer) oil change on my 55 plate Focus 1.6 TDCI this weekend and I'm looking to undergo some additional maintenance at the same time to make sure everything is running as smoothly as possible.

I'm keen to remove the Inlet Manifold to clean this out, as I would assume it has a lot of built up carbon in there after 12 years of running! (However it only has 70k on the clock!). I've looked around online and I can't seem to find a proficient guide as to how to remove it. Do I need to to take out the fuel injectors first? What pipes/tubing should be disconnected? Once removed can I just bathe it in carb cleaner and then flush it out with warm water?

I'd also like to blank my EGR at the same time, I've had the plate for yonks but it would seem the windscreen tray is glued on, so I had difficulty reaching the valve, although this was a year or so ago. My understanding is the EGR is to the left at the back of the engine. If I removed the manifold would I be able to access the valve to slide the plate in? And is it worth cleaning the valve first before blanking if this is the case?

I've attached a couple of images (not my engine) which may help someone point me in the right direction here. Any assistance whatsoever would be greatly appreciated!

As a final question, after the manifold is removed, is there then access to the rocker cover gasket? As I may have a slight leak so would be interested in replacing this too. I have a Haynes manual on order but I would love for some pros out there to give me some tips, or even provide images of what I need to disconnect remove. I'll upload some photos of the actual engine tomorrow when I have some light.

 

*Edit* I've received the Haynes, after reading through the removal process it seems quite straightforward. So now I'm just wondering the best way to clean it!

Thanks in advance for any advice! Regards, Sam

Edited January 25, 2017 by Sack13
Updated information.