R56CarbonBuildUpCleaning

ForallCooperS2007UpR56


Date:September2,2011
Revision:NC
Author:J.Pendlum(NAMUser:Texasmontego)


ISSUE: Carbonbuilduponthevalvesandintake
portsresultingindecreasedperformance


TOOLSREQUIRED
AirCompressorwithspraynozzle
Mediumsizemirror
Flashlight
Sockets:7,10&13mm,13mmDeepSocket
Ratchet&Extensions
T25&T27Torx
AssortedFlat&Phillipsscrewdrivers
Pick
Metal&nylonbristlebrushes
ChildrensToothbrushorsomekindofsmallbrush
HeavyDutyCarb&ThrottleBodyCleaner(Recommended:BerrymanB12Chemtool)
Shoptowelsorrags(thatcanbethrownaway)
Smallcontainerforscrewsandmisc.smallpieces
Safetyglasses

Note:
Anaircompressorisrequiredtodoathoroughandeasycleaningofthevalveports.Ifyoudonothaveaccesstoa
compressor,donotstarttheproject.Thecompressorisusedtoblowoutanypieceorotherdebrisfromtheportsduring
cleaning.

Disassembly

1. PutonSafetyGlasses.YouwillbeusingCarbcleanerwhichcandamageyoureyes.

2. Disconnectthepositiveterminalonthebattery(10mmsocket&smallratchet)

3. Removethetopoftheairbox.

a. Disconnecttheelectricalplug(Seearrow)

b. Qty.4T27Torxscrews(Seearrow)

c. Looseningthehoseclampwithaflatscrewdriver(Seearrow)

d. Liftuponthefrontoftheairboxandslidetowardsthefrontofthevehicle,andthendisconnectthehose.

Hose
Air Box Clamp

Electrical
Screws Screws Plug

4. Removethebottomoftheairbox.

a. RemovetheT27Torxscrewfromthepassengerssideoftheairboxbottom(Seepicture)

Screw

 b. Liftupwiththeairboxbottom.Thereare3grommetssecuringtheboxtothemanifold.

c. Rotatetheboxbackwardstodisconnectthehoseonthelowerrighthandside(Seepicture).

d. Makesuretoremovethegrommetsandstoreinasmallcontainerforreinstallation.

Hose

Grommets

5. RemovetheNoiseMakeandHoseassembly.

a. Usingaflatscrewdriver,loosenthehoseclampontheleftside(Seepicture).

b. WithaPhillipsscrewdriver,removethemountingscrewsecuringtheNoiseMakertotheintakemanifold(See
picture)

c. Disconnectthetubingfromthefirewallbypullingdown.

d. Removetheassembly(dependingontheageofyourvehicle,youmayneedtouseaflatscrewdrivertoloosenthe
hosefromtheexistingpipingontheleftside)

Noise Maker
already removed

Noise Maker Noise Maker

Hose Connection
Mounting to Fire wall
Screw
Hose Clamp

 6. RemovetheIntakeManifold

a. Disconnecttheelectricalconnectionlocatedatthetopcenterofthemanifold.

Electrical Plug

b. Disconnectthehoseatthetopofthevalvecover.Pinchthesidesoflockcollarandpullthehoseconnectionaway
fromthevalvecover.

Hose
Connection

Pinch
Valve Cover

c. Usingadeep13mmSocket,removetheQty.5nutssecuringthemanifoldtotheengine.

Nuts

 d. Withalongflatscrewdriver,loosenthehoseclamponthelowerendofthemanifoldassembly.

Follow this
hose down
to the hose
clamp

e. Removethemanifoldfromtheengineandrotateback.Thiswillexposetheundersideoftheintakemanifold
whereadditionalitemsneedtoberemoved.

f. Thereare2assembliesattachedtothemanifoldbyrubbergrommets(Seepicture).

Assembly #2
Assembly #1

 Grommet mount
Grommet mount location for
location for Assembly #2
Assembly #1

BOTTOM VIEW OF INTAKE

MANIFOLD

g. Slidebothassemblies/rubbergrommetsofftothesidedisconnectingthemfromthemanifold.

h. Disconnectthehosefromthemanifold.Pinchthesidesofthelockcollarandpullstraightout.

Hose on underside
of Intake Manifold

 i. DisconnecttheelectricalplugtotheThrottleBody,onthebottomofthemanifold.

Throttle Body
Electrical Plug

j. Removemanifoldfromvehicle.

7. Removethelargehoseonthepassengerssideoftheenginebay.

Caution:Becarefulremovingthehose.Itmaycatchonothercomponents

a. Useaflatscrewdrivertoloosenthehoseclampatthetopandremovethehose.

Hose

Hose Clamp

8. RemoveThrottleBodyfromIntakeManifold

a. RemoveQty.3,T27TorxscrewssecuringThrottleBodytoManifold.

9. Determinewhichvalvesareclosed.UsetheMirrorandFlashlighttoviewinsidetheintakeports.Dependingonthelevelof
buildupthismaybedifficult.

a. Thetwoouterportsandthetwoinnerportsruninsync.Ifyoucandetermineoneoftheouterportsisclosed,then
youknowtheotherouterportisclosedaswell.Visaversawiththeinnerports.

b. UsingtheCarbCleaner,sprayagenerousamountintotheclosedportsandallowsoakingforatleast1015
minutes.TheCarbCleanerwillpoolinsidetheclosedports.Ifitdoesnotpool,thenthatportisnotclosed.

 10. Inspectallpartsremovedfromthevehicle.Youwillnoticeanoilybuildupontheinteriorofallcomponents.Usingarag
andcarbcleaner,cleantheinteriorandexteriorofallcomponents.(Mythrottlebody,hosesandmanifoldhadextreme
buildup,soyoumayhavetousethenylonbrushtoremoveallresidue.)

CAUTION:Useonlynylon/plasticbrushesontheplasticpieces.Metalbrushescoulddamageimportantcomponents.

Notice the
Oily Build up

11. Cleanthe2closedports/valves.Thismustbedonebyhand.Donotuseadremel,drilloranymechanicaldeviceasthose
coulddamagethevalves

CAUTION:Makesureyouarewearingyoursafetyglasses.YoudonotwantCarbCleanerinyoureyes.

a. Usingthemirror(IfoundamakeupmirroratWalMartunder$5,anditprovidedagoodworkingsize)inspectthe
portstoseehow/whereyouwillbescrubbing.

b. Withachildrenstoothbrush(ThiswastheonlybrushIcouldfindthatwassmallenoughtofitintheportswhile
providingenoughbrushestocleanaroundthevalves)beginscrubbingtheport.

c. Thewholeportneedstobecleaned.Alternatebetweenthemetalbrushandthesmallbrush.Cleanthebrushes
periodicallytoremoveanylargepiecesyoumayhavereleasedduringscrubbing.

d. UsingtheAirCompressorandnozzle,blowouttheport.Youmaywanttosoakupsomeofthecarbcleanerbefore
youblowitoutasthisstepmakesamess.Beforeyoublowitout,covertheportwitharag/towel.

e. Usethepicktooltoscrapanythickorlargeparticlesinsidetheport.Iusedthepicktooltoremovethedebris
behind/aroundthevalves)

f. Repeatstep11untilthevalveisclean.Youmayneedtoallowthecleanertosoakforalongerperioddependingon
thelevelofbuildup.

Note:Dependingonthelevelofbuildup,youmayneedtorepeatthisstep5+times.

12. Closetheremaining2ports/valvesforcleaning.Youwillneedanotherpersonforthisstep.

a. Youneedtoclosetheother2portsforcleaning,buttheonlywaytodothisontheMiniistoturnthemotorover.
Asyouknow,withtheelectronicstart,thestarterwillcontinuetoturnuntilthemotorruns.Youonlyneedthe
motortoturnenoughtoclosetheother2ports.

Pullthe4sparkplugconnections/bootsfromthesparkplugs.Thiswillpreventanyaccidentalstarts.
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 Withasecondperson,connectthebatterybyholdingthebatterycabletothepositiveterminalofthebattery(use
aglove).Donottouchthemetalterminaloryoucouldgetshocked.

PutthekeyintheignitionandpushtheStart/Stopbutton.Thesecondthemotorbeginstoturn,havethesecond
personremovethebatterycablefromthebattery.

Note:FromthemomentyoupresstheStart/Stopbuttonuntilthebatteryisdisconnectedshouldonlytake12
seconds.

Checktoseeiftheothertwoportsarenowclosed.Iftheyarenotclosed,repeatStep12.

Onceyouhaveclosedtheremainingports,reinstallthesparkplugconnections/boots.

13. RepeatStep11tocleantheremaining2ports.

Reinstallation

14. ConnecttheThrottleBodytotheIntakeManifoldwiththeQty.3T27Torxscrews.

15. InstalltheHosetotheupperpipingonthepassengerssideoftheenginebay.Maneuverthehosedownbehindthemotor
intoposition.Connecttheupperconnection,butdonottightenthehoseclamp.(Ifthehoseisdifficulttogetonthe
connection,useasmallamountofWD40tolubricatetheend).

Hose to be
installed

Upper
Piping

 16. InstalltheIntakeManifold.

a. Connectthesmallhosetotheundersideofthemanifold(snapintoposition)

Hose on underside
of Intake Manifold

b. ConnecttheelectricalplugtotheThrottleBody.

c. Pressonthe2rubbergrommetassemblies(removedinStep6f&6g)andmakesureallconnectionstothese2
assembliesaresecure.

d. InstalltheIntakeManifoldonthetreadedstudsconnectingittotheengine.Usinga13mmDeepSocket&Ratchet,
tightentheQty.5nuts.(Besuretohandtighteneachnutbeforeusingtheratchet.Youwantequalpressureacross
all5nuts)

Nuts

e. ConnecttheHosetothelowerendoftheManifoldandtightentheupper(fromStep15)&lowerhoseclamp
securingitinposition.(YoucanuseasmallamountofWD40tolubricatethehoseend)

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 f. Connectthesmallhosetotheconnectionatthetopofthevalvecover.

Electrical
Plug
Hose
Connection

g. Connecttheelectricalplugtothetopoftheintakemanifold(Seepictureabove)

17. InstalltheNoiseMaker&hoseassembly.(TheNoiseMakerisntpicturedbelowasIremovedminepermanently.)

Noise Maker Noise Maker

Hose Connection
to Fire wall
Mounting
Screw

a. Attachthehosetotheleftconnectionandtightenthehoseclampwithaflatbladescrewdriver.

b. InstallthemountingbolttothecylinderNoiseMaker(Seepictureabove).

c. Snaptheendconnectiontothefirewall(Seepictureabove).

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 18. Installlowerairbox

a. Install3rubbergrommetsintothemountsontheintakemanifold.

Plastic Pipe

Grommets

b. Connecttheplasticpipetothelowerrightsideoftheairbox.Rotatetheairboxtolockthepipeintoposition.

c. Snapthelowerairboxintothe3grommetsandinstalltheT27screw.

Screw

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 19. InstalltheairboxTop

a. Cleanairfilter

b. Slidetherearoftheairboxintotheplasticlocks.

Hose
Air Box Clamp

Electrical
Screws Screws Plug

c. Connectthehosetotheairbox

d. TightentheQty.4T27screwsonthefrontoftheairbox.

e. Tightenthehoseclampwithaflatscrewdriver.

f. Plugintheelectricalconnection.

20. Recheckallhoseclamps,electricalconnections&oillevel.

21. ConnectPositiveterminaltothebattery&starttheMini.

22. Ifyougetanycheckenginelightsormessages,recheckallhoseconnectionsandelectricalplugs.

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