Letter 28052

How to clean deposits in an aluminum casting? [California] 

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My EGR system in my 1988 Honda Accord DX (with carburetor), failed because the passageway in the intake manifold, from where the EGR valve bolts onto the intake manifold to the inside of the manifold, is blocked by accumulation of exhaust carbon and other burned fuel deposits. The intake manifold is an aluminum casting. I removed the manifold (You can not believe how difficult a task that was.) in order to clean it. Now that it is off, I still can not see where the EGR passageway opens into the intake cavity of the manifold. I ran a 1.5' piece of speedometer cable into it, but got nowhere. Looks like the internal opening is hidden inside the manifold, on the other side of a partition or something. How do I clean it? What chemical will dissolve the sludge without etching the aluminum? Does it exist?

Eugene Debs Kelsey
User (Ineed to clean a casting) - Lockwood, California, USA

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