 | Home > Puma (Tdci) > Intake Manifold Removal and Replacement |
 
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 785  
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my memory lets me down now but I had my inlet manifold off last year... best I can remember is its best to give yourself as much room as possible by stripping away the water hoses and lp fuel pipes etc, and while it is possible to get the manifold off by just removing the egr valve motor in the end I removed the pipework as well to aid refitting... its a congested area on the 2.2 and like most things the more times you do it the more you know what you can get away without removing ..
ive added some photos which will give you an idea of what I ended up removing and some of the bits removed,, the throttle body connector needs a bit of attention unless you are really familiar with connecting and disconnecting it blind,,and hope it helps  Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge |
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30th May 2025 11:40am |
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| glassman Member Since: 30 May 2025 Location: Cape Town Posts: 7 
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Many thank Andy. Much appreciated.
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30th May 2025 11:56am |
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| glassman Member Since: 30 May 2025 Location: Cape Town Posts: 7
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Thanks again to Andy. I took your advice and removed anything i thought was in the way.
The only thing that remains is that throttle body connector (I think) which Andy warned me about. See pic. Appreciate any advice on how to remove this one. Does it have a lock mechanism? Does it pull off in the direction of the wire entry? Thanks again. |
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30th May 2025 4:03pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 785
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If i recall I got the manifold unbolted and movable.. the wire to the body comes up from below and there was a cable tie or clip i cut to give the loom a bit more movement and then I got the whole assembly into a position where I could determine the connector securing mechanism..nearly sure it's just a plastic clip that has to be depressed before pulling it apart..I may even have used a mirror..
If it doesn't get sorted I'll dig the borescope out and try and get a picture.. but it won't be today.. |
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30th May 2025 4:14pm |
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| glassman Member Since: 30 May 2025 Location: Cape Town Posts: 7
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Many thanks Andy. I'll have a go tomorrow afternoon and let you know.
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30th May 2025 6:05pm |
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| glassman Member Since: 30 May 2025 Location: Cape Town Posts: 7
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Just an update. I managed to disconnect the connector by first removing the throttle body. Based on Andy's advice I was able to loosen the manifold to give me enough space to get to the screws holding in the throttle body.
The connector does have clips on each side which you push in before pulling out the connector. One issue I found is that a previous owner appears to have had the EGR mapped out... so permanently closed... but not blanked off. I assume this as the water pipes were re-routed such that there was no water flow through the EGR cooler. Is this possible? And an OK solution? Should I install blanking plates? |
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1st Jun 2025 5:10pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 785
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Pleased you got that bit sorted..it's all very tight and fiddley down that side..
If you had any doubts about the starter motor or glow plugs now is the time.👍🤣.. On the egr valve.. mapping that out just means it's commanded shut all the time..but whatever engine management strategy is employed they say it still has to be electrically connected.. You could still add a blanking plate, but don't think its necessary.. The coolant flows through the egr valve and from the outlet on that it goes on to the egr cooler..before returning to the pump inlet..so it's an easy bypass ..if I was going to blank the egr line I think in your case I'd do so at the inlet to the egr cooler as its not in use by the sounds.. I keep meaning to check my electronic throttle body.. ive got a feeling its not in use as scan data on mine show the egr and throttle responses or commands never alter.. You might even have the dpf strategy mapped out as well if you have no egr function.. |
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1st Jun 2025 5:32pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2419
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Many rest of world 2.2’s I.e Australian 2.2’s did not have a DPF. The OPs one being South African may be one of these. Else yes the DPF would need to be mapped out AND removed, else it would clog if just mapped out.
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1st Jun 2025 6:13pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 785
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Ahhh yes ..more than likely..
Did they still have a cat? |
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1st Jun 2025 7:13pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2419
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Yes they still have a CAT , the ROW 2.2 downpipe is similar to the EU 2.4 in that respect.
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1st Jun 2025 7:30pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 785
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Thanks ian.. 👍
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1st Jun 2025 7:41pm |
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| glassman Member Since: 30 May 2025 Location: Cape Town Posts: 7
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Thanks Andy. I am wondering if the EGR cooler was bypassed as a temporary fix because it had a leak... and then never sorted out.
Is there any way of telling if the EGR is operating? I just guessed it was mapped out. I plan to blank it off anyway but not right now... I don't suppose it's a good idea to run the EGR without the cooler! Also, with the cooler bypassed, does this affect the water flow in the engine... and therefore the cooling? Lots to learn. |
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1st Jun 2025 7:49pm |
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| glassman Member Since: 30 May 2025 Location: Cape Town Posts: 7
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Thanks Ian.
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1st Jun 2025 7:50pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 2419
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If the EGR has been properly mapped out by say Bell Auto Serves (BAS), then blanking the EGR cooler at ingress and egress, then bypassing the EGR cooler and EGR cooling by removing the pipes and joining in the correct order will be fine.
In doing so you bypass the EGR cooler that as you say can leak. Which in turn can cause issues such as head gasket failure. |
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1st Jun 2025 9:01pm |
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