P010100 Melted intake manifold

[T6 Pilot]

Hi guys having a bit of trouble with this code
P010100
Cleared it gave it 50km test drive came back on with the EGR low flow code. Checked my voltages to Maff sensor and pressure tested boost system can’t see no leaks at intercooler.
Could do with a hand if someone knew correct voltage at maff sensor would be great. Transporter has CXHA engine

 

[T6 Pilot]

Hi guys up date original post I couldn’t update the title so started new thread. So drove the van a second time engine light came on same codes Mass air flow and EGR flow. Cleared codes went around 500 yards going perfect then went into limp mode. Checked codes P029900 active. Rama a turbo charger test thought what I could hear was boost leak checked and was leaking under intake manifold pressure sensor. Stripped the front off the Transporter as the intake is absolutely buried easiest way to get to the manifold. In the pictures is what I found looks like it’s melted from the inside out. Anyone ever experienced this I’m going to check the valves see if there’s a crack

 

[T6 Pilot]

Just up date guys
Replaced the intake manifold cleaned out to inlet ports of carbon as best as possible and Egr pipe checked valves using bore scope could see no damage. Built it all back up road test over 100 kms went well full power no faults. Time will tell if there’s anything else causing the manifold to melt

 

[n10n]

Another melted manifold: 18874 - Leak in Air Intake System - 23957 - Boost Pressure Regulation - 25958 - Boost Pressure Regulation

 

[Dellmassive]

i wonder whats causing this? . . . must be a lump of carbon build up and causing a hot spot.

 

[Dellmassive]

what was the rough strip down time to get the manifold out?

and what was the rough rebuild time - till road test?

 

[n10n]

i wonder whats causing this? . . . must be a lump of carbon build up and causing a hot spot.

Speculation: EGR output temperatures must be too hot. I think this could be the case if a) cooler does not work to cool off the exhaust or b) EGR valve does not stay closed when it should.

b) we’ve seen happening, during regens the valve should be closed but sticking valve does not close completely. Maybe some of too hot and diesel-moist exhaust then gets through and eventually burns holes to the manifold.

This is just thinking aloud though.

 

[T6 Pilot]

Another melted manifold: 18874 - Leak in Air Intake System - 23957 - Boost Pressure Regulation - 25958 - Boost Pressure Regulation

With the luxury of a two post ramp and Milwaukee tools I had the manifold off in around 3 hours. The front comes away nicely once off few coolant pipes and EGR loosening off engine loom then wiggle the manifold out. The front bottom intake bolt can be done with 3/8 wobbly and extension

 

[T6 Pilot]

Speculation: EGR output temperatures must be too hot. I think this could be the case if a) cooler does not work to cool off the exhaust or b) EGR valve does not stay closed when it should.

b) we’ve seen happening, during regens the valve should be closed but sticking valve does not close completely. Maybe some of too hot and diesel-moist exhaust then gets through and eventually burns holes to the manifold.

This is just thinking aloud though.

I agree. I have experienced EGR valves sticking open in the past melting the intake manifold pressure sensor. I ran a Egr valve test and it passed there was a low EGR flow code when I first brought the vehicle in after intake manifold replacement it did not come back into ECU. Il keep updated if there’s any more faults come into vehicle.

 

[T6 Pilot]

Another melted manifold: 18874 - Leak in Air Intake System - 23957 - Boost Pressure Regulation - 25958 - Boost Pressure Regulation

You have the same issues. Be good to see pic see if it’s the same spot. Mine appeared to be cylinder 3

 

[n10n]

You have the same issues. Be good to see pic see if it’s the same spot. Mine appeared to be cylinder 3

Wasn’t mine, I’m just following with interest and trying to find out if this could be seen from diagnostics earlier. @KC1 provided this picture - looks like little bit different spot but anyway near EGR end of the manifold

 

[T6 Pilot]

Yeah looks very similar possibly a little more melted. Mad how it looks like it’s been drilled from inside out

 

[Beaucowlin]

I have just came across the same problem on my t6 CXHA 150. I have just ordered a new intake manifold hopefully this doesn’t happen again as i have mow removed the EGR

 

[T6 Pilot]

I’ve seen no come backs on the manifold I replaced in March. I never did a EGR delete so hopefully replacing your manifold will fix the problem

 

[AdT6Kombi]

The root cause of this problem will be the EGR cooler leaking coolant, the glycol in the antifreeze ignites with the high exhaust gas temperatures the carbon/antifreeze ember burns and with the positive pressure in the intake manifold it is pushed out through the wall of the manifold.