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  1. #1
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    EGR/Intake Clean Questions

    Morning,

    I'm planning on removing and cleaning out the egr vale and intake manifold from my 2010 ZR on the weekend.

    The Toyota service manual makes the removal job look huge. It states that the wiper assemblies and cowl have to come out in order to get the EGR valve out, as well as draining all coolant from the system and removing heater and bypass hoses to remove the intake.

    My questions are:
    Is it possible to get the EGR vale out without pulling the wipers and cowl out?
    Can you work around the heater and water bypass hoses to get the intake out? Or is it necessary to drain the coolant and remove the hoses?
    After re-installing the injector fuel pipes, how do you bleed the air out of them before start up?

    Your pointers will be much appreciated.

    Cheers
    Will
    Last edited by Willstar; 20-04-2017 at 08:21 AM.

  2. #2
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    I did this job yesterday.Are you planning on taking it off up to the elbow, or the entire manifold? I can direct you through the process of the intake up to the elbow.

  3. #3
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    I plan to remove the manifold too.
    Did you get the egr valve out without having to remove the wiper assembly?

  4. #4
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    Yeah it's nowhere near the wiper assembly so no need to.
    Check this out, although it's a Hilux, as soon as you remove the intercooler (not required on the 150)it is exactly the same.
    http://www.newhilux.net/phpbb/viewtopic.php?t=8630

  5. #5
    Out of control poster! Anth120playdo's Avatar
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    Quote Originally Posted by Willstar View Post
    Morning,

    I'm planning on removing and cleaning out the egr vale and intake manifold from my 2010 ZR on the weekend.

    The Toyota service manual makes the removal job look huge. It states that the wiper assemblies and cowl have to come out in order to get the EGR valve out, as well as draining all coolant from the system and removing heater and bypass hoses to remove the intake.

    My questions are:
    Is it possible to get the EGR vale out without pulling the wipers and cowl out?
    Can you work around the heater and water bypass hoses to get the intake out? Or is it necessary to drain the coolant and remove the hoses?
    After re-installing the injector fuel pipes, how do you bleed the air out of them before start up?

    Your pointers will be much appreciated.

    Cheers
    Will
    My questions are:

    Is it possible to get the EGR vale out without pulling the wipers and cowl out? Yes, but very very difficult. It's easy to remove the wipers & cowl. If that's hard, forget the rest!

    Can you work around the heater and water bypass hoses to get the intake out? No

    Or is it necessary to drain the coolant and remove the hoses? Yes
    But You could plug the Hester hoses that go to the egr cooler, but your doing such a major job, you may as well flush & replace coolant.

    After re-installing the injector fuel pipes, how do you bleed the air out of them before start up?
    Prime the filter & make sure your battery is good.

    Your pointers will be much appreciated.

    A. With the questions you asked I'm concerned you don't know how big a job it is.

    B. very high risk of contamination to Injectors, removing pipes unnecessarily.

    C. Don't do it, just clean egr valve & elbow, as far as you can reach into the manifold is 95+% of it.

    D. Lots of things could go wrong, others have regretted it, don't do it.
    Cheers, Anth - Technician
    Prado 1kd-ftv D4d specialist

    FRESH Injectors @ 120,000k, ONLY use NEW DENSO & pipes
    NO CHIPS NO TUNE UPS - piston crack risk it - feeling lucky?
    Sorry

  6. #6
    Out of control poster! Anth120playdo's Avatar
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    Quote Originally Posted by JimmyC View Post
    Yeah it's nowhere near the wiper assembly so no need to.
    Check this out, although it's a Hilux, as soon as you remove the intercooler (not required on the 150)it is exactly the same.
    http://www.newhilux.net/phpbb/viewtopic.php?t=8630
    Disagree,
    Hilux & 120 Prado are completely different to 150.

    Hilux is the easiest.

    No need to remove wipers on vehicles with top mount intercooler.
    Cheers, Anth - Technician
    Prado 1kd-ftv D4d specialist

    FRESH Injectors @ 120,000k, ONLY use NEW DENSO & pipes
    NO CHIPS NO TUNE UPS - piston crack risk it - feeling lucky?
    Sorry

  7. #7
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    Thanks Anth.
    It's not a matter of not being capable, but the amount of time that I'll invest, rather than paying too have it done.
    I think your pointer on going as far as the elbow will be taken. I'll see how much gunk has accumulated and then re-evaluate.

  8. #8
    Out of control poster! Anth120playdo's Avatar
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    Quote Originally Posted by Willstar View Post
    Thanks Anth.
    It's not a matter of not being capable, but the amount of time that I'll invest, rather than paying too have it done.
    I think your pointer on going as far as the elbow will be taken. I'll see how much gunk has accumulated and then re-evaluate.
    It may look bad into manifold, but by the end of your fingertips at the most, should be thin coating.

    Then you can use intake spray after its back together.
    Remember it's all the way in ports & back of valves, if you do it, & get muck under valves & can end up with 0 compression & no go, then pull head off & send for cleaning.
    Cheers, Anth - Technician
    Prado 1kd-ftv D4d specialist

    FRESH Injectors @ 120,000k, ONLY use NEW DENSO & pipes
    NO CHIPS NO TUNE UPS - piston crack risk it - feeling lucky?
    Sorry

  9. #9
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    I'll check with a borescope too.

  10. #10
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    Sorry Anth,
    1 more question for you.
    Do you recommend using a flush before an oil change?
    Mine has 85000kms and previous owner had oil changes at 10000km intervals.
    Worth doing once?
    Worth doing every change?
    Thanks again.

  11. #11
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    I change my oil every 5k, Oil filter every 10k and use an oil flush every time I change the filter (10k). Seems to work for me.
    Stan Miko

    - 2007 120 Series 3.0L D4D

  12. #12
    Out of control poster! Anth120playdo's Avatar
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    I'd say the flush thing doesnt do much.
    The plate reducing the soot will do much more.

    Oil every 5k with plate & Im sure the oil will be clean & so will the internals.
    Cheers, Anth - Technician
    Prado 1kd-ftv D4d specialist

    FRESH Injectors @ 120,000k, ONLY use NEW DENSO & pipes
    NO CHIPS NO TUNE UPS - piston crack risk it - feeling lucky?
    Sorry

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