Nasty looking intake manifold!!

I am replacing the carb on the wife's 78 superbeetle vert and I
noticed that the interior of the intake manifold looks rather......
shall we say.. Unclean

It looks a little rusty (strange since it looks to be made of
aluminum???) and looks as if the paint on the interior is chipping
off.

Is this normal? I dont see any loose debris or obvious trash, but I
am concerned that this may affect performance or engine life
somwhat.

Anybody seen something similar? Should I be overly concerned?

Thanks
Jim

On Apr 15, 5:29 am, "fenderjw" > wrote:
> Is this normal? I dont see any loose debris or obvious trash, but I
> am concerned that this may affect performance or engine life
> somwhat.
>
> Anybody seen something similar? Should I be overly concerned?

I'm not entirely sure which parts you mean, but I think some of the
intake manifold is steel. Intakes do tend to get gunked up over time,
especially if the engine has functioning EGR and PCV. It can be a
problem if it get severe enough, but you're probably not close to that
yet. Could be affecting performance to a certain degree.

Wouldn't hurt to clean it out and give it a fresh coat of paint, some
rainy weekend.

Peace,
Harry

On Apr 16, 1:15 am, "Harry Smith" > wrote:
> On Apr 15, 5:29 am, "fenderjw" > wrote:
>
> > Is this normal? I dont see any loose debris or obvious trash, but I
> > am concerned that this may affect performance or engine life
> > somwhat.
>
> > Anybody seen something similar? Should I be overly concerned?
>
> I'm not entirely sure which parts you mean, but I think some of the
> intake manifold is steel. Intakes do tend to get gunked up over time,
> especially if the engine has functioning EGR and PCV. It can be a
> problem if it get severe enough, but you're probably not close to that
> yet. Could be affecting performance to a certain degree.
>
> Wouldn't hurt to clean it out and give it a fresh coat of paint, some
> rainy weekend.
>
> Peace,
> Harry

Thanks for the info Harry. I was talking about the portion of the
intake manifold just under the carb. I spoke too soon about it being
made of aluminum. It is simply steel painted "aluminum grey". I'll
give her a good cleaning before I reassemble the carb/alternator/fan-
shroud. Thanks again for your advice.

Jim

Update!
Removed the intake manifold under the carb and WOW! Tons of rust,
metal flakes the size of a quarter, and other crap had accumulated
there. I've cleaned all the major stuff out, but how should i clean
out an/or refurbish the inside of the manifold? Maybe its not worth
it and I should install another manifold altogether???

Jim

fenderjw wrote:
> Update!
> Removed the intake manifold under the carb and WOW! Tons of rust,
> metal flakes the size of a quarter, and other crap had accumulated
> there. I've cleaned all the major stuff out, but how should i clean
> out an/or refurbish the inside of the manifold? Maybe its not worth
> it and I should install another manifold altogether???
>
> Jim
>
>
>
Run a round wire brush thru it?

As for the possible vacuum leak at the unused port,
smear a bit of silicone (RTV) on the opening.

BTW, when you re-install the end castings, use gasket
sealant on the gaskets or else you will have mysterious
mis-fire problems.

Speedy Jim
http://www.nls.net/mp/volks/

"I have no use for a car which has more spark plugs than a cow has teats!"
Henry Ford, when advised that Chevrolet was introducing a 6-cylinder engine.

On May 6, 10:40 am, Speedy Jim > wrote:
> fenderjw wrote:
> > Update!
> > Removed the intake manifold under the carb and WOW! Tons of rust,
> > metal flakes the size of a quarter, and other crap had accumulated
> > there. I've cleaned all the major stuff out, but how should i clean
> > out an/or refurbish the inside of the manifold? Maybe its not worth
> > it and I should install another manifold altogether???
>
> > Jim
>
> Run a round wire brush thru it?
>
> As for the possible vacuum leak at the unused port,
> smear a bit of silicone (RTV) on the opening.
>
> BTW, when you re-install the end castings, use gasket
> sealant on the gaskets or else you will have mysterious
> mis-fire problems.
>
> Speedy Jimhttp://www.nls.net/mp/volks/
>
> "I have no use for a car which has more spark plugs than a cow has teats!"
> Henry Ford, when advised that Chevrolet was introducing a 6-cylinder engine.

Speedy Jim
Are you suggesting that I use gasket sealant on the metal gaskets at
the end casting - intake port or between the end castings and the
center part of the intake manifold (where the rubber addapters are)?

Thanks
Jim

On May 7, 7:59 am, fenderjw > wrote:
> On May 6, 10:40 am, Speedy Jim > wrote:
>
>
>
> > fenderjw wrote:
> > > Update!
> > > Removed the intake manifold under the carb and WOW! Tons of rust,
> > > metal flakes the size of a quarter, and other crap had accumulated
> > > there. I've cleaned all the major stuff out, but how should i clean
> > > out an/or refurbish the inside of the manifold? Maybe its not worth
> > > it and I should install another manifold altogether???
>
> > > Jim
>
> > Run a round wire brush thru it?
>
> > As for the possible vacuum leak at the unused port,
> > smear a bit of silicone (RTV) on the opening.
>
> > BTW, when you re-install the end castings, use gasket
> > sealant on the gaskets or else you will have mysterious
> > mis-fire problems.
>
> > Speedy Jimhttp://www.nls.net/mp/volks/
>
> > "I have no use for a car which has more spark plugs than a cow has teats!"
> > Henry Ford, when advised that Chevrolet was introducing a 6-cylinder engine.
>
> Speedy Jim
> Are you suggesting that I use gasket sealant on the metal gaskets at
> the end casting - intake port or between the end castings and the
> center part of the intake manifold (where the rubber addapters are)?
>
> Thanks
> Jim

Jim, I think he is talking about the ones between manifold and end
castings. The others are crush seals and should not have any kind of
sealant.

Anton

fenderjw wrote:
> On May 6, 10:40 am, Speedy Jim > wrote:
>
>>fenderjw wrote:
>>
>>>Update!
>>>Removed the intake manifold under the carb and WOW! Tons of rust,
>>>metal flakes the size of a quarter, and other crap had accumulated
>>>there. I've cleaned all the major stuff out, but how should i clean
>>>out an/or refurbish the inside of the manifold? Maybe its not worth
>>>it and I should install another manifold altogether???
>>
>>>Jim
>>
>> Run a round wire brush thru it?
>>
>> As for the possible vacuum leak at the unused port,
>>smear a bit of silicone (RTV) on the opening.
>>
>>BTW, when you re-install the end castings, use gasket
>>sealant on the gaskets or else you will have mysterious
>>mis-fire problems.
>>
>>Speedy Jimhttp://www.nls.net/mp/volks/
>>
>>"I have no use for a car which has more spark plugs than a cow has teats!"
>>Henry Ford, when advised that Chevrolet was introducing a 6-cylinder engine.
>
>
> Speedy Jim
> Are you suggesting that I use gasket sealant on the metal gaskets at
> the end casting - intake port or between the end castings and the
> center part of the intake manifold (where the rubber addapters are)?
>
> Thanks
> Jim
>

On the metal gasket (or even on the newer soft gaskets available
today. You cannot trust the gasket to seal properly.

Jim

anton wrote:

> On May 7, 7:59 am, fenderjw > wrote:
>
>>On May 6, 10:40 am, Speedy Jim > wrote:
>>
>>
>>
>>
>>>fenderjw wrote:
>>>
>>>>Update!
>>>>Removed the intake manifold under the carb and WOW! Tons of rust,
>>>>metal flakes the size of a quarter, and other crap had accumulated
>>>>there. I've cleaned all the major stuff out, but how should i clean
>>>>out an/or refurbish the inside of the manifold? Maybe its not worth
>>>>it and I should install another manifold altogether???
>>
>>>>Jim
>>
>>> Run a round wire brush thru it?
>>
>>> As for the possible vacuum leak at the unused port,
>>>smear a bit of silicone (RTV) on the opening.
>>
>>>BTW, when you re-install the end castings, use gasket
>>>sealant on the gaskets or else you will have mysterious
>>>mis-fire problems.
>>
>>>Speedy Jimhttp://www.nls.net/mp/volks/
>>
>>>"I have no use for a car which has more spark plugs than a cow has teats!"
>>>Henry Ford, when advised that Chevrolet was introducing a 6-cylinder engine.
>>
>>Speedy Jim
>>Are you suggesting that I use gasket sealant on the metal gaskets at
>>the end casting - intake port or between the end castings and the
>>center part of the intake manifold (where the rubber addapters are)?
>>
>>Thanks
>>Jim
>
>
> Jim, I think he is talking about the ones between manifold and end
> castings. The others are crush seals and should not have any kind of
> sealant.
>
> Anton
>

No, I'm talking about the "crush" gaskets.

Yes, they worked fine at the factory when everything
was spanking new and flat and in perfect alignment.
When you are working with old parts which are difficult to
return to "factory fresh" condition, you have to make
allowances.

I've heard far too many agonized stories from others
about engines that wouldn't idle properly due solely to
very tiny vacuum leaks at those gasket connections.

BTDT,
Jim