My intake ports @ 150k miles (NASTY!..)

I finally tackled this job a few weeks ago. I was not expecting nice looking intake ports after those 150k miles but what I saw was way beyond my imagination.
Just wanted to share a few pictures for you. You are looking at the #4 cylinder intake. Picture taken as soon as the manifold was removed. I didn't touch anything. The carbon pieces could easily be finger picked!..

I was originally thinking the intake cleaning would take me a day or two in the garage. But after seeing how bad the intake ports were, the total job took several days, countless hours of tedious cleaning with different methods.
I was able to clean all 4 intakes to a decent level but I couldn't reach the end of each intake and clean the walls around the valves. It would have been possible to remove those carbon built-up but wouldn't have been possible to remove them entirely. I even tried a strong shop vac. It didn't work.

After cleaning the intake manifold (Yes, it was full of oil!..), the ports, and the PCV (it was still rattling @ 150kmiles), I did an oil change and installed an oil catch can. This was 1000 miles ago. All is working fine so far.
I replaced intake manifold and throttle body gaskets, PCV cleaned up not replaced.

Soon, I will be replacing the spark plugs, getting down to EGR cooler and clean that part as well. I expect a similar condition down there.

I used NutzAboutBolts videos. Thanks to them for everything...

 

Nope, it doesn't consume oil. More accurately, it doesn't consume enough to the point that I realize and add oil.
Every high mileage car should consume some oil I guess.
Plus all that oil goes from PCV into the intake should count as consumable

 

You mean how many of those 150k miles were ICE vs EV miles?

If so, I would love to know that as well. My buddy has Ford C-Max Energi and his onboard computer records total EV miles vs ICE (gas engine) miles. Anytime the ICE is off and the wheels are rolling counts as EV miles.

 

My first idea was to soften the buildup with brake/carb cleaner and use a wet cloth (soaked with brake cleaner) to wipe the inner surface of each intake port. It seemed to work but the buildup was so thick that I wasn't getting anywhere. I had to find a more effective method.
I checked the intake valves and except for the cylinder #1, all were closed. Being extra cautious with cylinder #1, I shoved piece of cloth into each intake port all the way to the valve area. I made sure valve areas sealed well. Then I took my trusty flathead screw driver and started scraping the intake surfaces one by one Once the thick material was out (and you wouldn't believe the amount of stuff I got out!..), it was easy to clean the remaining thin layer of carbon with a help of brake cleaner and paper towel.
This cleaning didn't get done in a few hours though. Took several days of tedious cleaning. I did clean the entire carbon deposits (or whatever it was) off the intake port surfaces. Did check the valve area with an inspection camera and utility mirror to see if anything large dropped in there. Small pieces shouldn't have been a problem since some must have been already being sucked into the cylinder every day.
I do remember picking up a few pieces with a curved tweezer. I also used a shopvac but I didn't find it effective. I didn't have the right attachment to do a good job in that tight area.
Overall, I did pretty well. Maybe it wasn't necessary to do this level of cleaning but since I was already there, I said why not? and did it.
One cannot pay me to do it once again though. I am done with it for good

And as for the injector tips, I was being careful with them. I cleaned the buildup around the tips but didn't touch the tips directly.

Next up is the infamous EGR cooler...

 

80% of the cleaning done was on the engine block. Just a little part was on the manifold itself. You aren't getting away with any of those cleaning jobs if you get that manifold replaced

 

Every 50k miles. Wow. You worse than me. I won't ever see that portion of my car ever again...

I installed a catch can and I believe in it. However, I do not think all that carbon rubbish is the result of oil getting into the intake. EGR system must be responsible for some of it.

 

You are absolutely right. My car was running the same way before and after. I didn't realize anything (nor was I expecting). It is just us DIYers get bored time to time and we love our cars.
I would recommend cleaning the intake (getting that puddle of oil out of there) and installing a catch can (if a person can do it). That should be enough. No crazy cleaning as I did here will be required...