how to remove 1KZ intercooler and clean throttle body

[the ferret Junior Member Find all posts View Profile Close the ferret]

Great thread.
Maybe a little bit of the topic but it has been discussed,

Do injectors need service/replacement after (x) amount of KM?(mine is now at 175000km and runs great) Should i be concerned?

Do glow plugs need service/replacement after (x) amount of km.?

After reading this ,I now need to rip off the inter cooler and check the muck factor.(Bugger)

Russ

While yer at it mate, block the EGR, fit a catch can and you won't have to do it again (cleaning everything out I mean), Those first pics of that disgusting filthy intake and rocker cover can only be put down to emission control laws that I am not a big fan of!! rant over!!

[paul2 Junior Member Find all posts View Profile Close paul2]

Hey Damonat and Tassie Tiger (and any others that have done the job...), did you worry about that "slimey gunky sticky goop" - as you so nicely described it Tassie Tiger - getting dropped down the 'throat' of the the throttle body or the inlet ports on the head as you were cleaning it? Or will that just be burned up by the motor... or what? I got a funny feelin' mine is 'chokas' as I can even see some weeping of a slight film of the 'goop' around the base of the throttle body, where the gasket is between it and the intake manifold. And that thing of mine just has to look at a slight hill (which is all we have here in the NT anyway!) and it 'kicks back' a gear, and I'm flat out gettin' 1100ks out of 180L...!

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

Hey Damonat and Tassie Tiger (and any others that have done the job...), did you worry about that "slimey gunky sticky goop" - as you so nicely described it Tassie Tiger - getting dropped down the 'throat' of the the throttle body or the inlet ports on the head as you were cleaning it? Or will that just be burned up by the motor... or what? I got a funny feelin' mine is 'chokas' as I can even see some weeping of a slight film of the 'goop' around the base of the throttle body, where the gasket is between it and the intake manifold. And that thing of mine just has to look at a slight hill (which is all we have here in the NT anyway!) and it 'kicks back' a gear, and I'm flat out gettin' 1100ks out of 180L...!

you need to remove the intake manifold to be able to properly clean it.
the stuff is that sticky, i had trouble wiping it off my screwdriver when removing the bulk from the head ports.
i then wrapped a rag around my screwdriver, dampened it in PULP and then cleaned the head ports. left it for a few hours to evaporate before refitting intake manifold.
the difference is wow.
now the wife drives it without the steinbeauer 'on', and that has never happened. i would get yelled at for turning it off.
it runs just so much better, and has so much more power/torque. i suppose you get that when you can breath properly.
my fuel economy has improved. now don't need to sink pedal to the floor.
mine was doing the hole as soon as it hits a hills, no go. now just cruises over.
i would make an EGR gasket and forget the centre hole, who ever does this job.

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

Great thread.
Maybe a little bit of the topic but it has been discussed,

Do injectors need service/replacement after (x) amount of KM?(mine is now at 175000km and runs great) Should i be concerned?

Do glow plugs need service/replacement after (x) amount of km.?

After reading this ,I now need to rip off the inter cooler and check the muck factor.(Bugger)

Russ

injector are meant to be replaced ever 150000kms.
you will never pick any running great issues, as they happen so slowly you get used to them.

glow plugs.
you can test your glow plugs for resistance with the intercooler removed and BUSbar removed.
i found 1 of mine was open circuit (didn't pick it), so replaced it at the same time.
be sure to buy genuine or good quality ones.
you don't want any bits of the glow to fall off and damage your engine (this is highly likely if the tip breaks).
toyota recommend replacing the injection pipes every 150000kms, but i have never done this to any vehicle (mine or customers). and never been any problems.
i think their reasoning is the injection pulses are such high pressure, that over time and vibration a crack could occur.
i agree it could, but i haven't worked on extreme usage/condition vehicles, so most city cars may be fine.
mine vehicles may require this if kept for extended periods

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

another possible cause of this build-up, and which hasn't been mentioned yet,
is the use of too thin engine oil.
this does enter the intake from the turbo (bush lubrication).
you can pick up on this when air filter to turbo pipe, and turbo to intercooler pipes are removed.
look into turbo and the intercooler side will show carbon/oil runs/ridges.
also the intercooler supply side will have the same build-up.
i did, as toyota dealer have been using there bulk oil (10W/30 VVTI oil) as i forgot to request toyota bottled deisel oil.
i have have the intercooler off many times and since the use of the thin oil, this has occured.
i have had the interccoler off many times and i only notice this after i forget to request the use of the toyota bottled diesel engine oil.
change it over, it's good again.
i'm only talking a small amount but over 100000+km it will build up and especially when the EGR carbon hits it. instant goop

[Russ WA Senior Member Find all posts View Profile Close Russ WA]

Thanks Damonat for the advise,
I just got back from my local Fuel injection place to get a idea on costs.

GPT-225 Bosch glow plugs around $22 each. Made in Germany I guess.
Exchange injectors $77 each .

Now all I need to do is get some gaskets and get dirty.
Cheers Russ

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

Hey Russ

Can you post details of where you got quotes from.
I need some for my Hilux, and will want to do a comparison to local guys who can charge extortionist prices.
Plus will check my Prado glow plugs soon due to some hard starting on cold mornings recently

[Russ WA Senior Member Find all posts View Profile Close Russ WA]

Hi DAZ ,

Allied Diesel and Turbo. 08 9409 5700
10 Dellamarta Road Wangara.

Cheers Russ

[Russ WA Senior Member Find all posts View Profile Close Russ WA]

Well after playing around I have discovered that after 175000km the GOOB build up was considerable.

I managed to round a 12mm nut on the manifold,(BUGGER)the hidden one closest to the fire wall and had a S**T of a time to remove it ,finally I had to borrow a impact socket of a mate.(I hate my 1/2 " Sidchrome socket set ) .
After getting a 13/16th long socket to remove the injectors( And a long pole) I found they are similar to a dirty spark plug,black and full of carbon, not having seen used one before I don't know if this is standard but will get them exchanged.
I'm now trying to work out what size spanner I need to take off the BIG NUT behind the EGR thing that is preventing me removing the manifold.

Cheers Russ

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

Hi DAZ ,

Allied Diesel and Turbo. 08 9409 5700
10 Dellamarta Road Wangara.

Cheers Russ

Thanks Russ
Im thinking I will be doing mine over school holidays, plus the 5L Hilux which I already know is clogged

[the ferret Junior Member Find all posts View Profile Close the ferret]

Well after playing around I have discovered that after 175000km the GOOB build up was considerable.

I managed to round a 12mm nut on the manifold,(BUGGER)the hidden one closest to the fire wall and had a S**T of a time to remove it ,finally I had to borrow a impact socket of a mate.(I hate my 1/2 " Sidchrome socket set ) .
After getting a 13/16th long socket to remove the injectors( And a long pole) I found they are similar to a dirty spark plug,black and full of carbon, not having seen used one before I don't know if this is standard but will get them exchanged.
I'm now trying to work out what size spanner I need to take off the BIG NUT behind the EGR thing that is preventing me removing the manifold.

Cheers Russ

Pretty disgusting state of affairs, considering it's sposed to be a u bute whiz bang modern engine.
And that's the bit you can see!! I would be taking all steps possible to prevent this, after all it's not a five minute job is it?
Cheers, ferret.

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

If you spray the egr nut with wd40 and leave overnight you should be able to crack it with a shifter and spin it off with your finger. Its slightly tapered so once cracked comes undone easily - or it should.....

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

I'm now trying to work out what size spanner I need to take off the BIG NUT behind the EGR thing that is preventing me removing the manifold.

Cheers Russ

32mm spanner

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

Guys - any ideas on what the glow plugs and the injectors will set me back, and what brand/s should I be going with for these? Is it ok to go with remanufactured injectors?

Cheers
Ian.

[Russ WA Senior Member Find all posts View Profile Close Russ WA]

Replaced mine today ,$396 total for 4 x injectors overhauled and 4 new Glow plugs.
Now to rebuild the engine .

Russ