Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal

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Tue 2 Aug 2011 22:39
Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal - CharlieNib89

Hi...I've got a problem, (well obviously)

I have a Ford Focus 1.8 TDCI 2006 (Lynx Engine), the "Engine Systems Fault" message has come up, frankly I'm too cheap to go to the Ford garage for them to tell me the code. I am in "limp home mode" so driving is a no go.
I am certain it is my EGR though, all the symptoms fit.
I removed the EGR cooling pipe and sure as shootin even it's full of carbon.
The problem is the egr is integrated into the inlet manifold...which didnt seem like a problem till I realised a sadist designed this engine. Apparently Hitler has returned and he is designing engines for Ford!!

I have removed the egr cooling pipe, the doofer from the top of the inlet manifold with the electrical attachment (forgot its name, it is secured by 4 torx screws), removed the easy accessed bolts from the back of the manifold. However the remaining bolts are blocked by the exhaust manifold...so do I need to remove it? How is that done as it is a royal pain in the kiester to remove too?

Am I missing a trick? The egr is a part that does need cleaned, so why make it this hard?
Someone suggested spraying carb cleaner into the main breather tube of the I.M. while the engine was turning over...I nearly died! Surely that wouldn't clean the egr out and wouldn't it over combust the engine? That can't be the way to do it, can it?

I can supply photos if needed.
Please help!

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Wed 15 Jun 2016 20:14
Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal - Sclillis

Did you get this sorted? Im trying to remove the exhaust manifold but now im hitting a wall.

How did you get on ?

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Tue 26 Jul 2016 22:55
Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal - rhian morgan
please tell me someone has found the secret of how to get that bolt out of the back?? one last one but its in a b**** of a place cant get a turn on at all (ford focus 2003 tdci)
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Thu 22 Dec 2016 22:38
Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal - Ruain

I've created an account for the sole purpose of finding the solution to that b***** bolt.! Did you manage it in the end? Even contemplating welding spanners tomorrow in an attempt to get the angle and torque.

I've seen pictures of these manifolds where people (who couldn't be bothered to detail the process) take them out, and they're absolutely Filthy. My car, 2010 1.8tdci, is at home in pieces while I borrowed the wife's car today.

Tomorrow I shall continue the battle, armed with new stubby spanners and longer, thinner 10mm ring spanners. It would bother me to have to put it all back together, after taking the time to get to the stage I'm at., so many pieces off just to do simple maintenance.

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Fri 23 Dec 2016 09:39
Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal - Railroad.

Sadly there is no product that you can spray into the air intake that will do this job for you. Removal of the parts and manual cleaning is the only way. Once they are removed I would recommend using a 50/50 mix of heavy duty traffic film remover and water. After scraping off the worst first, soak the manifold in the solution for about 24 hours. It will come out spotless. Do not use TFR neat. It will not be as effective, and you will never get it off if it dries, so mix it with water. Ensure all parts are completely dry before you reassemble them.

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Mon 26 Dec 2016 19:58
Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal - Ruain

Do turbo and exhaust manifold need removing? I've managed to remove all bolts and nuts that are keeping the manifold/egr lump in place and can rock it around and it's almost free but it seems that the exhaust needs dropping in order to wrest the inlet manifold free. I've the majority of the donkey work done. That 13mm bolt in behind the turbo inlet is a horrible one, managed it though.

Car is outside so I lost the light as I was beginning to figure it all out. Tomorrow will see the manifold/egr lump off once and for all.

I'll post a pic of my success and before/after cleaning. I can see between the ports and the manifold now and there's unbelievable sludge buildup. I've got a crazy assortment of chemicals and I'll be power washing it and steam cleaning everything until they're brand new.

Don't think turbo needs removing, just the exhaust manifold backed up a tad.

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Wed 28 Dec 2016 11:01
Ford Focus - Ford Focus 1.8 TDCI 2006 EGR + MANIFOLD removal - Ruain

Well, can confirm that the manifold does NOT need to come off, nor does anything else (other than the egr cooler).

I removed all the bolts on the exhaust manifold, then eventually, via a lot of manouvering removed the final two hard to reach bolts at each end on the underside of the inlet manifold....and the final 13mm nut on the bottom, in the middle.

Then to remove the EGR/inlet manifold assembly, I drove a few plybars down between the engine block and exhaust manifold (without damagain the gasket) and that gave me enough wiggle room to remove the cursed inlet manifold/EGR assembly.

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