johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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ive fitted an aftermarket inlet manifold, from a user on MIG. ive fitted everythin including all new gaskets etc, but now the car isnt drivable.
it idles at 1.5k revs, goes up and down, and also stalls.
when i put my foot on the gas, its very lumpy, and revs awfully.
im unsure of whats wrong with it. can anyone offer any help?
Im thinking it may be the ICV, but dont know what to look for in the engine bay to find it.
also, smoke is coming from the oil breather hose where i put a small pipercross filter on. any idea why?
any help greatly appreciated.
John
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Corsa E-Tec
Member
Registered: 4th Feb 04
Location: Stevenage Drives: Leon Cupra
User status: Offline
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not sure on the smoke part.
cleaning the ICV will need doing but not 100% on it's location 
did you disconnect the battery before changing the maniflold?
if not, disconect the baterry for 5 mins then start car and leave to idle for 5 mins.
[Edited on 16-02-2006 by Corsa E-Tec]
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Dean_W
Member
Registered: 13th Dec 05
Location: Downham Market, Norfolk
User status: Offline
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John,
Any pics of said manifold, and the connections?
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johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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yeah just a sec mate il go and get some pics
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Dave A
USER UNDER INVESTIGATION - DO NOT TRADE
Registered: 10th Dec 03
Location: County Durham
User status: Offline
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try cleaning icv, check all the vaccum hoses, paticularly the map sensor.
also check for an air leak around the joints and where the bolts go through the box as these seem a poor design on these inlets
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johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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Corsa E-Tec
Member
Registered: 4th Feb 04
Location: Stevenage Drives: Leon Cupra
User status: Offline
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the loose hose needs to be connected to the FPR hose. that goes into the inlet manifold.
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broster
Premium Member
Registered: 6th Dec 02
Location: Drives: E39
User status: Offline
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his FPR is connected...
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johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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connected to the new inlet are the FPR, MAP and brake servo
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Dean_W
Member
Registered: 13th Dec 05
Location: Downham Market, Norfolk
User status: Offline
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On mine, the small rocker cover hose is attached to the new manifold, with T pieces in to attach all the other vacum hoses to e.g. yellow, black, FPR etc.
Must have missed one?
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Dean_W
Member
Registered: 13th Dec 05
Location: Downham Market, Norfolk
User status: Offline
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John,
I'm on my way home now, i'll take some close up pics of the hoses on my mantzel and post when i get in.
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Dave A
USER UNDER INVESTIGATION - DO NOT TRADE
Registered: 10th Dec 03
Location: County Durham
User status: Offline
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get the other two solenoids fitted
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johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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good man.
unsure of where to fit those otehr pipes though!
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Dave A
USER UNDER INVESTIGATION - DO NOT TRADE
Registered: 10th Dec 03
Location: County Durham
User status: Offline
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on both solenoids one pipe goes to vaccum from the inlet. use some t-pieces.
the other goes to:
Charcoal canister solenoid: long pipe coming from the inner drivers wing, hard black plastic pipe.
secondary air pump solenoid: pipe that comes from the valve on top of the exhaust manifold
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Rob B
Member
Registered: 8th Jan 04
Location: Area Motorsport Drives: Race EP3
User status: Offline
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sounds like the map sensor to me 
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broster
Premium Member
Registered: 6th Dec 02
Location: Drives: E39
User status: Offline
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below the brake servo line you have a vacume line that not got anything connected to it..... get a vacume line on that, will help the idle a bit.... unmetered air will get thru there raising the idle a bit
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johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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yeah im going to get a t piece and get that into a vacuum line
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Dean_W
Member
Registered: 13th Dec 05
Location: Downham Market, Norfolk
User status: Offline
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John,
A couple of pics so you can see the vacum pipes: -
From the rocker cover to the one of the take offs from the brake servo hose. T pieces that the FPR and the black plastic hose that comes from the right hand side of the engine bay goes into.
The yellow plastic hose goes onto the other take-off on the brake servo pipe.
MAP sensor straight onto the new manifold.
Brake servo on to the new manifold.
More pics in garage if you need them
[Edited on 16-02-2006 by Dean_W]
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Corsa E-Tec
Member
Registered: 4th Feb 04
Location: Stevenage Drives: Leon Cupra
User status: Offline
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quote:
Originally posted by broster
below the brake servo line you have a vacume line that not got anything connected to it..... get a vacume line on that, will help the idle a bit.... unmetered air will get thru there raising the idle a bit
thats what i meant 
T pieced on the FPR hose
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broster
Premium Member
Registered: 6th Dec 02
Location: Drives: E39
User status: Offline
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no i mean on his inlet there is a fitting thats no got a hose on it...
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Dave A
USER UNDER INVESTIGATION - DO NOT TRADE
Registered: 10th Dec 03
Location: County Durham
User status: Offline
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Corsa E-Tec: i think that pic is from one i made earlier! where did you find it?
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johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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wheres the fitting on the inlet with no hose??
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broster
Premium Member
Registered: 6th Dec 02
Location: Drives: E39
User status: Offline
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am i wrong
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Corsa E-Tec
Member
Registered: 4th Feb 04
Location: Stevenage Drives: Leon Cupra
User status: Offline
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dunno what that is mark. but i thought it was meant to be T peiced to the FPR vacum hose.
808: it was in your garage,  sorry mate, didn't think you would mind.
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johnscorsaXE
Member
Registered: 14th Sep 04
Location: Walsall
User status: Offline
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that thing that has been circled is just a thin bolt that is on the lower inlet. not a connection point iirc
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