Now I'm finally back at home I've started the process of replacing the EGR valves on the FF.

Whilst removing the intake manifold I noticed (well it was difficult not to!) that the post-EGR portion of the manifold is pretty gunky with soot. Interestingly the driver side one is oily gunk whilst the passenger side is dry soot. Although I did have the driver side one have a split pipe a while ago, the passenger one did not.

I've started cleaning up the manifold with elbow grease and diesel (some of which has ended up on the dog).

The question is - now that I've got this far - do I remove the intake manifold that's sat on top of the cylinder head (which requires removing the injectors and then sourcing the necessary parts to refit them) and clean that up as well? Or just leave as is (there haven't been any recurring faults to indicate the injectors need looking at) and let the new EGR valves (hopefully) do their work and clean up some of the gunk that's there.

The intake side of the intake manifold (lots of intakes and manifolds here) from the intercooler is clean - albeit with a very light smattering of oil so there isn't crap being introduced from there meaning that all this is from the EGR valves.

Click image to enlarge

When I did the thermostat housing on our vehicle, I noticed too the oily sooty deposits on the drivers side bank and the dry sooty deposits on the passenger side.
I thought a turbo problem regarding the oils seals, etc.
Turns out it is the crankcase breather is drawn into the engine on the drivers side and burnt off hence the oily deposits on that side.
I would not bother cleaning the rest of the manifolds, except for the one you took off.

Steve. 1968 Series IIA Pastel Green, nearly there project

Clean the poor dog.... forget the manifold....

Get one of these to have a good look...

http://www.ebay.co.uk/itm/2M-6-LED-USB-Wat...SwUdlWeMp2 Pete
I now have permission from the boss to use Y.O.L.O. Enjoy life
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Steve - thanks for clarifying about the breathers. I did wonder if there was something along the lines of that going on. Haven't got around to the WSM yet sk you've saved me some reading.

Pete - I might have to grab one of those. Oh and the rate she's moulting at the moment it'll be gone by tomorrow. It's tough enough trying to get that gunk off myself let alone a pup who just wants to play. Ed