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  • 1KD Intercooler

    Does anyone have any accurate information on whether you can run a D4D with the intercooler removed? I want to de-crud the intake throat with some Threebond diesel conditioner and have received conflicting information from 2 separate Toyota workshops. One says not a problem, the other says not to because there's an airflow sensor that will shut the engine down if the engine is run with the intercooler removed. They also said you will get an error code that has to be reset at the dealer.
    Which is correct? The Threebond product says you only need to run the engine for a couple of minutes while you spray it directly into the throat but I am unsure if it's OK to do so.
    [color=#BF0000][i]2016 200 Series GXL, Turbo Diesel, ARB BB, GME3520 UHF[/i][/color]

  • #2
    I don't know the answer to your question but.... I did want to do mine as well as soon as I got the time.
    I was speaking to my good friend, who has been a mechanic for the past 35 years, and runs a 4wd service and repair business. We have been friends for 25 years, and I trust his judgement.
    He was a little concerned at letting all of the crud go through the engine, and said that he just did a D4D Hilux last month by removing the whole assembly, and cleaning it all out away from the vehicle. He blocked off the EGR as per the customers wishes after that.

    He admitted it was a good deal more work, but advised me not to do the spary thing to mine.
    My vehicle has now done 80k and I have noticed a reduction in economy of about 15% in the last 40k.

    What to do??????

    I am leaning towards a total removal and cleanup, rather than the spray thing. Just letting you know that this is the advice that I have received.

    Steve
    2008 Diesel Prado with extra stuff added. I drive it on the road and other places too.

    Comment


    • #3
      Bidla,

      You can test this for yourself by taking the air flow sensor out of it's mounting in the air box then try to start and rev the engine. I sprayed the Threebond in before the turbo through the airbox.
      2019 GXL, Bullbar, UHF, Redarc Brake Controller, Tow Bar, Secondary Fuel Filter

      Comment


      • #4
        The Toyota workshop that said not to run the engine with the intercooler removed also said they had done quite a few of these de-crudding jobs but the way he said to do it was to remove the intercooler, spray the Threebond product into the throat, let it do it's stuff for a few minutes and then replace the intercooler before starting the engine. He said the engine may "ping" for a little bit due to the product but that will clear (do diesels ping?).
        gxl_d4d, on an earlier thread about the 1KZ intercooler, someone mentioned doing an oil change soon after using the Threebond product? Did you have a pinging issue?
        [color=#BF0000][i]2016 200 Series GXL, Turbo Diesel, ARB BB, GME3520 UHF[/i][/color]

        Comment


        • #5
          i've looked into the service book for the d4d and it does not mention anything about cleaning of the throttle body, is this really required or just good thing to do?

          Comment


          • #6
            Hi poirek,

            After reading an earlier post on cleaning a 1KZ throat I though that it was probably a certainty that a 1KD would develop that same sort of crud. A few PP'ers have asked that question about a 1KD but to my knowledge nobody has done the complete clean with photos. My economy and performance has gradually been eroding over many months and I think some of the problems may well be attributed to the build up in the airways.

            gxl_d4d, if I take the air flow sensor out of it's mounting in the air box then start and rev the engine and it shuts down and I get error codes what is the impact? Will I be able to replace the sensor and then be able to start the engine? Will I also have to go to a Toyota dealer to have the error codes reset?
            [color=#BF0000][i]2016 200 Series GXL, Turbo Diesel, ARB BB, GME3520 UHF[/i][/color]

            Comment


            • #7
              When I sprayed the stuff in, I used the flexible nozzle supplied with the can. There flow was very slow. Not sure if this is normal or the nozzle was blocked. It didn't spray out with pressure as you'd expect from an aerosol can. I didn't get any pinging with the Threebond. When I had Wynns EGR3 sprayed in, the engine did ping but the flow out of the EGR3 can was a lot faster than the Threebond. I'll check one of my spare cans to see if this is normal.
              2019 GXL, Bullbar, UHF, Redarc Brake Controller, Tow Bar, Secondary Fuel Filter

              Comment


              • #8
                I've done the three bond on my d4d and yes the engine does run without the intercooler. works good I wrote up about this on the 1kz thread
                It dosn't ping just blows some smoke out the exhaust for a minute

                I've asked around a bit about changing the oil after doing it and getting mixed responses with no-one being a deffinate yes or no I haven't asked toyota yet. they use a different branded spray, that does same thing, I don't want to change the oil as I did the oil change just before doing the spray but I'll keep asking and probly do it just incase

                Davros your mechanic mate who cleaned the d4d hilux tell you about the fuel lines to be removed to get the intake manifold of which are single use? or are they different to the prado? and at $150 x 4 also makes it bloody exspensive which is where I looked at a different option and found the threebond spray

                removal of the intercooler is easy the rest is a pain in the butt. other then fuel lines to be removed (and single use) you have the egr intercooler aswell.

                The egr is located just behind the throttle body and appears easy to get at. I didn't remove and block of the egr as the gaskets to refit the throttle body was a 4 day wait from toyota, so plan ahead

                mine has done 100000k opposite the egr inlet there was a 20mm build up I used 2 cans of threebond diesel conditioner
                worth the effort I will do this next service again and plan ahead so I can block of the egr

                Comment


                • #9
                  Davros your mechanic mate who cleaned the d4d hilux tell you about the fuel lines to be removed to get the intake manifold of which are single use? or are they different to the prado? and at $150 x 4 also makes it bloody exspensive which is where I looked at a different option and found the threebond spray
                  No Peter, that wasn't discussed. I am fitting my new suspension in his workshop, this coming Saturday. Throttle bodies and crud buildup will definately come up in conversation then.

                  Steve
                  2008 Diesel Prado with extra stuff added. I drive it on the road and other places too.

                  Comment


                  • #10
                    Well I ended up taking the intercooler off this afternoon and having a look at the throttle body.

                    Mine was really very clean, and I didn't end up doing anything except blocking the EGR vacuum line and putting it all back together.

                    Took less than an hour all up.

                    Here are some piccies. Engine is just shy of 80,000kms. I always use fuel conditioner.
                    Attached Files
                    2008 Diesel Prado with extra stuff added. I drive it on the road and other places too.

                    Comment


                    • #11
                      mine took the spray to get that clean

                      Comment


                      • #12
                        Davros, it's really interesting that your throttle body was so clean. In a previous thread on how to remove a 1KZ intercooler and clean throttle body a PP'er called DAZ has provided a link to a Hilux web site (NewHilux.net) and there's a guy on there that has done a very comprehensive procedure (+ pictures) on dismantling, cleaning and reassembling a D4D throttle body right down to the inlet manifold. Some of the replys to his thread from other D4D users show throttle bodies with substantial amounts of crud built up around the throat. Many of these guys have 150K + on the clock. You mentioned that you use an additive, which I don't so I'll be very interested to see how much crud has built up in mine at around the 95,000 klm mark.....
                        I have the word document on the detailed procedure if anyone wants it. It's really quite good and provides step by step instructions.
                        [color=#BF0000][i]2016 200 Series GXL, Turbo Diesel, ARB BB, GME3520 UHF[/i][/color]

                        Comment


                        • #13
                          I signed up and had a look at that article while I was at work yesterday, and it is the article that motivated me to have a good look when I got home from work.
                          I wasn't going to dismantle it any further even it was filled with crud. Just wanted to get an idea of the build-up, before discussing further with my mechanic friend.

                          Yes, I use a fuel additive and always have done. I haven't missed a tank fill since I bought the Prado at 23,000kms.
                          I just mentioned it, because I was just as surprised as you at the lack of build-up, and the consistent use of the additive is the only variable I could think of.

                          Steve
                          Davros
                          Advanced Member
                          Last edited by Davros; 13-09-2011, 12:49 PM. Reason: egr disconection has now been reversed
                          2008 Diesel Prado with extra stuff added. I drive it on the road and other places too.

                          Comment


                          • #14
                            Originally posted by Bidla View Post
                            Davros, it's really interesting that your throttle body was so clean. In a previous thread on how to remove a 1KZ intercooler and clean throttle body a PP'er called DAZ has provided a link to a Hilux web site (NewHilux.net) and there's a guy on there that has done a very comprehensive procedure (+ pictures) on dismantling, cleaning and reassembling a D4D throttle body right down to the inlet manifold. Some of the replys to his thread from other D4D users show throttle bodies with substantial amounts of crud built up around the throat. Many of these guys have 150K + on the clock. You mentioned that you use an additive, which I don't so I'll be very interested to see how much crud has built up in mine at around the 95,000 klm mark.....
                            I have the word document on the detailed procedure if anyone wants it. It's really quite good and provides step by step instructions.
                            I'll be very interested in this article and also what is the brand/name of the addtitive Davros is using?

                            As far as I've been told these common rail diesels don't like anything else in the fuel (and they need good fuel too = BP)

                            Comment


                            • #15
                              pjorek, can you PM me with an email address and I'll forward you the document
                              [color=#BF0000][i]2016 200 Series GXL, Turbo Diesel, ARB BB, GME3520 UHF[/i][/color]

                              Comment

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