how to remove 1KZ intercooler and clean throttle body

[ScoticusMaximus Member Find all posts View Profile Close ScoticusMaximus]

no problem, i only knew because i have read this thread start to finish a few times...

[Scottage Lurker Find all posts View Profile Close Scottage]

Hi Guys, just did my 2004 1KZ, has 330,000 on the clock, but we've only had the car for the last 50,000 so I'm not sure when the last time this was done. Was bad enough that the sludge was climbing up the pipe above the throttle body, so took off the manifold and did the petrol soak, and the plastic spatula and rag to the intake ports. Have also put through a can of EGR4 from the filter box, and an oil/filter change to finish off. Haven't done the gasket fix, but will be doing it next time as I'm not keen to revisit this job too often. The junk on the cardboard is just out of the ports, and the half inch of sludge in the soak bucket is just a little scary to think the cars working with that much of a handicap.

Just wanted to say thanks to everyone who's contributed to this thread, made the long job easy as possible. Is running like an absolute dream and has made the chip and exhaust bill even more liveable. Brilliant.

[Scottage Lurker Find all posts View Profile Close Scottage]

Just another pair of before and after pics. Thanks again Lads.

[tassie tiger Advanced Member Find all posts View Profile Close tassie tiger]

I pulled the intercooler off the other day. Here is a shot after 35000k with a disabled EGR system.

Sweeeeeet!

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

I know this is an old thread but was hoping someone from Brisbane that has done this could spend 15 minutes talking me through it in person, I have 210,000kms on my 1Kz so think it will need a clean.. I just don't want to attempt this clean and blanking plate install without visually seeing what has to be done first. I dont mind doing it but will feel a lot more comfortable with a how to sessions before hand.. I can come to you

[tassie tiger Advanced Member Find all posts View Profile Close tassie tiger]

I will be moving to Pottsville in a week and would be happy to help once settled.

Daz

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

Thanks Daz, but wheres Pottsville? 8-|

[znelbok Member Find all posts View Profile Close znelbok]

I pulled the intercooler off the other day. Here is a shot after 35000k with a disabled EGR system.

Sweeeeeet!

How did you disable your EGR?

i pulled the inter-cooler off on Saturday and as expected it has junk through the intake. Checked the glow plugs as well while at it and I pulled the vacuum hose off the EGR and blocked it.

It gave me a chance to have a look around a bit while the cooler was off and I know understand where the blanking plate goes, but I am unsure as to why to add one if you can just remove the vacuum hose to the valve.

Just got to plan to get the new gaskets now and then pull it all apart again for a thorough clean out.

@whiteknightoz - just open the bonnet and have a look at it. Its pretty simple in that its only a couple of bolts and two hose clamps to get the cooler off. Start with that and you will work yourself through it easily.

Mick

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

Got into this job today, My work lets there staff use the workshop for their own vehicles which was handy for this job.

My rig is coming up to the 300k mark so i decided to do it all while we were there, Injectors, Glow plugs , EGR blanking plate and clean the throttle body and inlet manifold.

Glad this job doesn't happen to often as it was a dirty as. Heres some picts of the filth.

On the drive home i could instantly feel the difference in the response when accelerating, fingers crossed for a bit better mileage out of the tank

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

I'm glad I found this thread as I have been wanting to do this job for a while. Now I've compiled a 'How To' and a 'Parts Required' list, this job will be done at the next oil/filter change in 4000km's time.

[BlakMoth Avid PP Poster! Find all posts View Profile Close BlakMoth]

I'm gonna give it a go soon too. Just need to order all the bits and make sure I have the right tools


Sent from my iPhone using Tapatalk

[hughesyp Lurker Find all posts View Profile Close hughesyp]

Thanks to all who have contributed to this thread as it was very useful information when I performed this clean. Found a good handfull of sludge inside my throttle body and inlet manifold which, when removed has given me a whole heap more power down low that the missus even commented on!

For all those thinking about doing this my advice is go for it but replace gaskets where you can particularly the inlet manifold to block (x4), and the throttle body (mine was already leaking prior to this which may have also contributed to the drop in power).

The biggest PITA was loosening the EGR via the "big nut". I managed to get my inlet manifold off first and once removed had a bit more room to access it. Just put a bit of wood between the firewall and EGR and heaved. Apart from that it was relatively straight forward but took a little while in the backyard.

EGR now "out of order"!

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

oh yeah and after cleaning throttle body, manifold and new injectors still running at 16.8 lt per 100km with 265 70 17 that is according to trip computer so not totally accurate.
Anyone got any ideas why its using so much juice??

Have you still got your car and did you get your issue resolved and are willing to post your solution?

I have been getting bad consumption and low ower. Went from averaging around 13.5/100 to 16 to 17/100. I thought I had actually resolved my issue when I cleaned out the MAP filter - but a few days later and it seems bad again - From reading this post I suspect the whole thing is so gunged up the filter is already dirty again.

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

EGR now "out of order"!

Not sure i understand how you go thte EGR out of order/blanked? was it using a block of wood or was to help leaver out the inlet manifold?

[Happyjack Lurker Find all posts View Profile Close Happyjack]

Prado 1kz_TE 3l turbo egr plate etc

This thread was great - even though I found it after I started the job.
I ordered the plate from Smithies Outback, very helpful (and in the meantime I've ordered the Provent 200 catchcan and will pick up the hoses etc locally as I may have to mount it on the inlet side of the engine (ABS breaking and dual battery fitted in front drivers side). A New Year job, including remove & clean the exhaust manifold.
A bit of a mission to get at the EGR inlet to the inlet manifold, just kept removing things until I could open up the gap to slide the slotted plate in.
One problem, one of the wiring plastic connectors had heat hardened and the securing lug you have to squeeze broke.
What - it was the wrong size!
Retrieve invoice from bin and read it - for the 4.2l engine???
Check my on-line order.
Oops , somehow ordered the wrong one
Sit & thinks, if I cut off one of the lugs it will still sit on the stud and still seal shut. Check with Smithies, yep will be ok as no real pressure on the plate anyway. ( later found I had a bit of stainless in a tool box I could have cut one out of in a mates workshop ). I'll make and replace when I do the catchcan and manifold
Got it in and tightened up.
Cleaned some crap out of manifold where i could and vacuumed i9t out ( I live on my own so no complaints from 'er indoors.
Cleaned up the butterfly fly valve with a brass scraper I had made up some time ago for cleaning old gaskets on the boat engine
( another life, another whole story but she was a beauty ),
washed with solvents and dried.
Bought new tube and s/st screw clamps,intercooler to butterfly.
I decided I might as well also clean out the intercooler, so sealed up the plastic outlet and sprayed degreaser in a number of times, swishing, rotating and emptying, then did same with some petrol followed by kerosene until kero ran clear.. Final rinse with acetone and left to evaporate.
Then decided to straighten out the bent fins - obviously done by bug bugs. Using a jewellers srewdriver I either bent them back straight or removed the top couple of mm with fine long nosed pliers. The worst sections for some reason were the outer 2 runs each side. When I do the manifold I'll be doing it in my mates workshop so will be able to give it a gentle blowout.
Reassembled and started up, sounded sweet but engine warning light on. WTF.
Found i had missed a connector to the air/pressure gauge doohickey.
All sweet.
Now for a long run - the Prado, not me. Time for shower and something refreshing.