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how to remove 1KZ intercooler and clean throttle body

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  • how to remove 1KZ intercooler and clean throttle body

    i thought it was time to check and clean the throttle body and butterfly on the 1KZ prado.
    thought it would also help others if i took some pics to show how easy it is.
    tools needed;
    3/8 drive rachet and 6inch wobble extension,
    10mm and 12mm short 3/8 drive sockets,
    multigrips,
    magnetic tray to store nuts or bolts once removed.


    takes about 5-10minutes to remove intercooler.
    it's just the intercoolers rear bolt that is hard to access with your hand to remove the bolt, but a magnet is good here.

    time to inspect the throttle body and butterfly.


    now i used a can of carby/throttle body cleaner and a old toothbrush and a clean rag once finished.


    so much cleaner looking.
    whilst i had the cooler off, i checked my glow plugs. found #4 glow plug cracked and broken.
    tested all glow plugs with a meter. only the 1 (open circuit) was bad.
    turned the engine over to blow out any carby cleaner from cylinders.
    now just put it all back together and drive it.
    [url=http://www.fuelly.com/driver/damonat/prado][img]http://www.fuelly.com/smallsig-metric/50578.png[/img][/url]

  • #2
    Re: how to remove 1KZ intercooler and clean throttle body

    nice job , but now for the stupid question how and why does it get so dirty?
    stepped up the a 200 LC for towing,
    but had a 2012 and 2010 150 Prado GXL auto diesel in Graphite with Bridgestone D697 A/T. Dobinson C59-300/325 and Bilsteins. Accessories : two baby seats. Sidewinder`s Dual Battery isolator and rear power outlet kit. Pirana Battery tray, Hayman Reese towbar with Toyota wiring kit and Brains`s guard.

    Comment


    • #3
      Re: how to remove 1KZ intercooler and clean throttle body

      Originally posted by maxjj
      nice job , but now for the stupid question how and why does it get so dirty?
      and i'll back that up with another one, what does cleaning it do for you? (i.e. cleaner means better air/fuel/some other stuff flow = better responsiveness/fuel economy/something else?)

      looks like nice and simple job, i assume not part of any "standard" service?

      Comment


      • #4
        Re: how to remove 1KZ intercooler and clean throttle body

        Originally posted by McBAIN
        Originally posted by maxjj
        nice job , but now for the stupid question how and why does it get so dirty?
        and i'll back that up with another one, what does cleaning it do for you? (i.e. cleaner means better air/fuel/some other stuff flow = better responsiveness/fuel economy/something else?)

        looks like nice and simple job, i assume not part of any "standard" service?
        after 200kms of driving today, the effects are,
        smoother stronger accel from standing start (probably from better flow into cylinders),
        ability to maintain speed without kicking back (4 adults in vehicle and hills that normally would kick down gear with 2 adults easily cruised up and over without strain, reving or kick-back).
        the reason it gets dirty as it is a restriction in the intake system and fine dust and oil vapour from engine blow-by mix to produce a sticky goopy substance.
        it then builds up and slowly chocks your intake (in this vehicle the throttle body).
        an engines air filter can't filter every partical (size wise, filters measured normally in microns).
        our prado has 150000+kms on it, and i'm sure this would be the first time it is checked/cleaned.
        around the butterfly it creates vacuum/pressure which the 1KZ has 2 outlets for sensors.
        if these get build up over them, then the ECU is fed the wrong info and the ECU outputs the wrong info and you can get poor results (fuel consumption, drivablity, hard starting etc).
        the results are not different if you did it to a petrol carby/injected engine. better flow, response, mileage. never a negative.
        [url=http://www.fuelly.com/driver/damonat/prado][img]http://www.fuelly.com/smallsig-metric/50578.png[/img][/url]

        Comment


        • #5
          Re: how to remove 1KZ intercooler and clean throttle body

          The crud build up is from EGR gasses mixing with crank case oil fumes. Nissan Patrols were suffering from holed pistons due to a similar thing as the build up got so thick that it would restrict air flow into the cylinders.

          There is a spray available form Wynns that does this clean for you without having to remove the intercooler. It's called Wynns EGR3. I don't believe it's available in retail, it needs to be purchased from a workshop.

          There's a thread on this forum that shows the intake of a D4D that has holed a piston. Have a look. This will give you an idea of how thick the intake sludge can build up. There might be some merit in doing the intake clean ever 100 000km.

          The throttle body clean will only clean the throttle body, it won't clean the intake manifold and runners.
          2019 GXL, Bullbar, UHF, Redarc Brake Controller, Tow Bar, Secondary Fuel Filter

          Comment


          • #6
            Re: how to remove 1KZ intercooler and clean throttle body

            on the Subaru (petrol) they put an upper engine cleaner in every service, it feels more responsive after.

            So why not have an upper engine cleaner on a diesel, is it worthwhile to use the wynn EGR3 every service or every year?

            http://www.wynnoil.co.uk/products-wynns ... d-egr3.htm
            stepped up the a 200 LC for towing,
            but had a 2012 and 2010 150 Prado GXL auto diesel in Graphite with Bridgestone D697 A/T. Dobinson C59-300/325 and Bilsteins. Accessories : two baby seats. Sidewinder`s Dual Battery isolator and rear power outlet kit. Pirana Battery tray, Hayman Reese towbar with Toyota wiring kit and Brains`s guard.

            Comment


            • #7
              Re: how to remove 1KZ intercooler and clean throttle body

              Can this black build-up be stopped by blocking the EGR valve as per this thread?
              [size=1][i][b]2004 GXL | Turbo Diesel | Manual | [/b]ARB Deluxe Bar | Safari Snorkle | Dual Batteries | ARB Compressor (mounted under hood) | Brake Controller | Uniden UH-012 UHF | TP09X1 Head Unit | [url=http://www.pradopoint.com/showthread.php?15100-Spoony-s-04-GXL-Turbo-Diesel]My Rig Build Up[/url][/i][/size]

              Comment


              • #8
                Re: how to remove 1KZ intercooler and clean throttle body

                This is an interesting subject that has prompted further research. Well I have now well and truely alarmed myself with this discovery - so what do others have to say? Is it worth while booking the Prado in for a clean of the entire throttle body and inlet manifold? How come this hasn't been discussed on PP?





                and here's the website

                http://www.patrol4x4.com/forum/showthread.php?t=51656
                Black 2003, TD, GXL Prado

                Comment


                • #9
                  Re: how to remove 1KZ intercooler and clean throttle body

                  after that it reinforces my decision to remove mine and have it cleaned next week.
                  now i have info to have approved by the minister for fun
                  [url=http://www.fuelly.com/driver/damonat/prado][img]http://www.fuelly.com/smallsig-metric/50578.png[/img][/url]

                  Comment


                  • #10
                    Re: how to remove 1KZ intercooler and clean throttle body

                    Originally posted by damonat
                    after that it reinforces my decision to remove mine and have it cleaned next week.
                    now i have info to have approved by the minister for fun
                    Please keep us posted, would like to see what you find. :?
                    Black 2003, TD, GXL Prado

                    Comment


                    • #11
                      Re: how to remove 1KZ intercooler and clean throttle body

                      yer will take before and after pics
                      [url=http://www.fuelly.com/driver/damonat/prado][img]http://www.fuelly.com/smallsig-metric/50578.png[/img][/url]

                      Comment


                      • #12
                        Re: how to remove 1KZ intercooler and clean throttle body

                        Cant count how many diesels I have rebuilt and have never seen it like that. Interesting :shock:
                        2009 120 V6 Auto. 265/70/17 Goodyear Silent Armours. Bilsteins and Kings Springs.

                        Comment


                        • #13
                          Re: how to remove 1KZ intercooler and clean throttle body

                          Damonat,

                          Can you take photos of the EGR bolts so you can give us an idea of how to remove it. The EGR valve and cooler will most likely also be filled with crud.

                          Thanks,
                          2019 GXL, Bullbar, UHF, Redarc Brake Controller, Tow Bar, Secondary Fuel Filter

                          Comment


                          • #14
                            Re: how to remove 1KZ intercooler and clean throttle body

                            I've been meaning to do mine for ages ... so with inspiration from this thread ... I did.

                            Armed with my wife's toothbrush and my daughters pj's I got to work and these are the final results:

                            Before:


                            After:


                            I will definitely be doing the entire inlet manifold when I get a bit more time, it's absolutely disgusting in there (I imagine it would look similar to that Patrol one).

                            Initial seat of the pants results from a drive around the block is smoother acceleration, so I'm happy with the result.
                            [size=1][i][b]2004 GXL | Turbo Diesel | Manual | [/b]ARB Deluxe Bar | Safari Snorkle | Dual Batteries | ARB Compressor (mounted under hood) | Brake Controller | Uniden UH-012 UHF | TP09X1 Head Unit | [url=http://www.pradopoint.com/showthread.php?15100-Spoony-s-04-GXL-Turbo-Diesel]My Rig Build Up[/url][/i][/size]

                            Comment


                            • #15
                              Re: how to remove 1KZ intercooler and clean throttle body

                              i ran out of time to have this done before the GTG.
                              will be doing this shortly after returning.
                              this will also give me an idea as to how much affect the EGR is having.
                              if butterfly is found to be getting dirty already, then i'll make my own gasket (without the hole) to fix that.
                              if it appears ok, i'll leave it.
                              will take pics either way.
                              will be sending inlet manifold away to be professionally cleaned, to ensure it is done properly.

                              PS
                              i have had my exhaust/dump pipe done since cleaning the throttle body.
                              i have so far picked up 100+ extra kms over both tanks.
                              not sure which gave me this, but it is a totally much nicer vehicle to drive now.
                              in the days prior to exhaust it was better, so i'll never know exactly
                              [url=http://www.fuelly.com/driver/damonat/prado][img]http://www.fuelly.com/smallsig-metric/50578.png[/img][/url]

                              Comment

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