1KD Intercooler

[simcott Lurker Find all posts View Profile Close simcott]

Dueler120
Thank you for the concise reply, I should get sterted as soon as possible and run the stuff through before the service.
I don't expect much gunk in the intake as the vehicle has only done 60K.
Thanks again.
Cheers

[Dueler120 Senior Member Find all posts View Profile Close Dueler120]

Yeah mate mines nearly done twice the amount as yours and was relatively 'clean'. Good luck with it and let us know hoe you go. Maby a few before and after shots of your opened butterfly if you have build up to see is it does the trick. Ill let you know how it goes for me. Drop the oil as soon as its done and your done and put the good stuff back in. With your new catch can you should be sorted from here on in.

[simcott Lurker Find all posts View Profile Close simcott]

Hi, I just did the 60K service and took the intercooler off to get at the EGR and the throttle valve. It was pretty ghastly from the EGR down. I cleaned all the EGR and throttle valve. Because I was having so much fun I got a suitable spoon from the kitchen and dipped down into the elbow as far as it would reach. out came the blackest black pudding I have ever seen. Even the white bits were black.
It all went back together without trouble so now I will try and get some of the reccomended product to loosen up the remainder over a period of time. hopefully that will keep it under control, now with the catch can installed.
Next service I will check the oil filter pickup screen after seeing what some of you have found.
Thanks for all the suggestions.

[simcott Lurker Find all posts View Profile Close simcott]

EGR matters.
I have been trying to get some Wynn's EGR3 but no one stocks it, let alone heard about it. I called the Perth Wynn's agent and they said that EGR3 is not supplied to retail?? only fuel injection service and such.
I phoned United Fuel Injection and they said that they wont use any liquid through a diesel while it is running? any thoughts?
I think that the best way in the end is to take the intake manifold off and clean it all properly and since that entails injection pipe removal I don't think I will bother.
I am still not convinced that sending a fine mist of solvent through the system will ever clean it out properly.
Cheers

[pjorek Advanced Member Find all posts View Profile Close pjorek]

double post

[pjorek Advanced Member Find all posts View Profile Close pjorek]

I'm still in doubt whether to use sprays to clean the intake. I bought some cans of JLM cleaner but haven't used them yet.

[Bushbasher Out of control poster! Find all posts View Profile Close Bushbasher]

Come on. You are only moving air through the intake so any resistance caused by a thin film of oil coating the intake is only going to have a minimal effect. Carbon fouling on throttle body will probably have a bigger effect.

[Dueler120 Senior Member Find all posts View Profile Close Dueler120]

Finally got around to spraying a can of JLM intake cleaner through the prado this arvo. I put half the can through the intake before the turbo and then pulled the intercooler off and sprayed some straight down the butterfly/ into the elbow. While spraying short bursts before the turbo I noticed the engine rev out each time. When I sprayed it directly into the butterfly then reconnected the intercooler and started the engine it was hesitant to turn over but when it did there was noticeble smoke from the exhaust. The smoke cleared in seconds and everything went back to normal.

I did take it for a spin and have to say there is a slight difference in the throttle response. More so evident when taking off from a standing start, but there is improvement. I did not expect a drastic change as my intake was fairly clear before the cleaning spray application. I will add it to the servicing regime as I believe it will have more of an effect over a longer sustained application.

Once It was run around the block a few times I cooled the engine and dropped the oil and ran some diesel conditioner through the fuel tank.

Cheers,

[gxl_d4d Advanced Member Find all posts View Profile Close gxl_d4d]

How much did you spray into the intake without the engine running? This is a risky thing to do. Too much fluid will hydraulic the motor and detonation from the egr cleaner igniting with the piston in the wrong position could hole a piston, bend a rod or damage a head.

[Mal Lurker Find all posts View Profile Close Mal]

Hello All, while I had the intercooler off to fit a catch can I thought I'd pull apart the intake and EGR on my 120 D4D and give them a clean out. As mentioned by DAZ there's an excellent set of instructions on newhilux.net that takes you step-by-step through the whole process. I'm now at the point of removing the elbow from the manifold - the prado differs from the hilux in having a large wiring loom with a plastic shroud covering the rear of the elbow (the hilux engine has an easily removeable water hose) and I'm blowed if I can work out how to get a socket or spanner on the rear two bolts as the plastic loom shroud almost covers them - see attached photos. Ideally the loom could be shifted so all 3 bolts could be accessed by socket, but I can't get it to move. Has anyone who's pulled apart the throttle body had similar problems?

[ROB83R Junior Member Find all posts View Profile Close ROB83R]

Ratchet spanners maybe?

[Rick NZ Member Find all posts View Profile Close Rick NZ]

spent the afternnon on my 120's 1KD

Uprated the 2micron racor 120 series to a 230 series ( had found that the smaller racor was fine, but due to its size (small) was pretty much clogged after 8,000km

Decided to haul the intake manifold off - (as it wasnt cleaned when the injectors were done by TNZ)
1.5hrs later - found heavy deposits through the intake system from the EGR valve onwards
These engines run a variable intake system to aid low rpm air speed into the cylinders - the head and intake has 8 ports - 4 are used at low rpm and all 8 at high rpm
my variable intake butterflies were held open and over 50% of the intake ports area blocked by deposit build up
A combination of brakleen , throttle body cleaner and combustion cleaner was needed to dislove most of the deposits
2 hrs of scraping and scrubbing - the intake was clean and the variable intake was free to move again afetr the 3 cupfulls of sludge removed
reassembled everything - and went for a wee drive

Massive increase in throttle reponse ! form standing start and also on the open road
Engine is even quiter than it was - putting this down to the fuel filter upgrade

Without doubt the worst intake I have done, and with the amount of deposits removed i would never entertain the idea of intake spray cleaner on a dirty intake
-as all the deposits would just end up in the cylinders

Pics to follow soon

[simcott Lurker Find all posts View Profile Close simcott]

RE Catch can. I just did the 70K service and I drained the catch can. About 50 Mls of oil and close to 90 mls of water condensate. I also checked the oil intake screen and that looked fine.