how to remove 1KZ intercooler and clean throttle body

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

Wonder if mine had been off before?

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

After having a 3" exhaust fitted a few weeks ago, I had my throttle body, inlet manifold and intercooler cleaned last week along with new glow plugs. Mechanic was amazed how much build up there was in the inlet manifold and suggested maybe the turbo was worn and sending an oil mist through. Prado starts well and runs well however not sure whether I can feel any better performance after the cleanout. Any of you diesel mechanics out there care to comment on the mechanic's suggestion that the turbo is maybe worn? He is looking for a reason for the large build up. 4by has done over 211,000klm's so it must be worn however hopefully not worn out?
Cheers.....Wayne

[Schaffer Addicted PP Member Find all posts View Profile Close Schaffer]

Anyone looked at blocking of the EGR to stop the build up of this crap?

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

After having a 3" exhaust fitted a few weeks ago, I had my throttle body, inlet manifold and intercooler cleaned last week along with new glow plugs. Mechanic was amazed how much build up there was in the inlet manifold and suggested maybe the turbo was worn and sending an oil mist through. Prado starts well and runs well however not sure whether I can feel any better performance after the cleanout. Any of you diesel mechanics out there care to comment on the mechanic's suggestion that the turbo is maybe worn? He is looking for a reason for the large build up. 4by has done over 211,000klm's so it must be worn however hopefully not worn out?
Cheers.....Wayne

I wouldn't be overly concerned Wayne... Read right through this thread mate as it explains why the build up is caused...

Have you found that it seems to run smoother though and is a little quieter?

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

A lot of this oily buildup in the inlet is caused by the PCV, "positive crankcase ventilation" on many diesel engines.
The oily mist "blowby" is fed directly into the inlet manifold, and condenses and forms a buildup of crud, for want of a better word.
Fitting a "catch can" can considerably reduce this problem.
The oily mist gathers inside the manifold and then the carbon introduced by the EGR valve, sticks to the oily residue and builds up over time creating friction against the incoming air needed for combustion, so... blocking the EGR will prevent a lot of this buildup.
The cleaner and smoother the inside of the inlet manifold, the more responsive the engine will be.
Cheers Rod. the "Bush Mechanic"

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

Question, with the Blocking the EGR pipe,( Which I have done)Will that alter the fuel economy?

Isn't it there to use up unburnt diesel that is coming out from the exhaust manafold pipe and hence giving you better economy.

I haven't used a tank of fuel since doing mine but I appears the fuel economy may be suffering,I will know more once I can get a fresh tank in.

Cheers Russ

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

I'm still yet to tackle mine, but will do some over the school holidays I think. Just out of curiosity, is it possible to remove all of the injectors without removing the manifold? The throttle body definitely needs to come off to get to the rear 2 injectors, but not sure whether the manifold needs to come off too. I may not take the manifold off if it isn't too dirty, and if I can change the injectors without doing so that would be fab and make the job so much simpler. Unfortunately, my manual is not very clear at all when it comes to injectors.....

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

yes you should be able to get the injectors out without removing the manifold. I removed the fuel lines out of interest when I was looking at mine so I can't see why the injectors couldnt be removed as well, there is plenty of room there.

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

ferret, you are the second person to suggest a catch can. I think the Nissan boys use them on the notorius 3L. Will look at the scope when I return from our trip up North. Gotta be better than pulling it apart and cleaning it. Mine was so crudded up the mechanic gave up with carb cleaner and outsourced the cleaning to a workshop with an agitating parts washer. Havn't got the bill yet but it won't be pretty. Working under the bonnet of the Prado myself doesn't do the back any good at all
Cheers...Wayne

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

Question, with the Blocking the EGR pipe,( Which I have done)Will that alter the fuel economy?

Isn't it there to use up unburnt diesel that is coming out from the exhaust manafold pipe and hence giving you better economy.

I haven't used a tank of fuel since doing mine but I appears the fuel economy may be suffering,I will know more once I can get a fresh tank in.

Cheers Russ

It is my understanding the the exhaust gasses are recirculated to a certain extent to satisfy emission control criteria, in order to be used on our roads.
The EGR only operates in the open position when you take your foot off or cruising under low load so that says to me that it's not there to conserve fuel..
A filthy conglomerate of carbon and soot in the intake manifold and the throttle body will cause poor fuel economy.
A clean throttle body, clean MAF and clean inlet manifold can only improve fuel economy.

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

ferret, you are the second person to suggest a catch can. I think the Nissan boys use them on the notorius 3L. Will look at the scope when I return from our trip up North. Gotta be better than pulling it apart and cleaning it. Mine was so crudded up the mechanic gave up with carb cleaner and outsourced the cleaning to a workshop with an agitating parts washer. Havn't got the bill yet but it won't be pretty. Working under the bonnet of the Prado myself doesn't do the back any good at all
Cheers...Wayne

Yes Wayne, the catch can is very important on the ZD30, it removes most of the oily mist that is intended for the intake.
It sticks like honey and then the soot sticks to that, that is where all of that gunk comes from, the crank case and the exhaust system via the EGR valve.
Cheers , the ferret.

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

Well I cleaned mine yesterday.
Holy Jesus, I couldn't believe the amount of build up after 110k. This is def EGR build up. I can safely say EGR build up wont be a problem again on this car.
Mine was a scrape & soak in petrol job. I took plenty of pics, but they are similar to already posted, so wont bother.

Couple of tips for those DIY.
Check that you do actually have all the tools ready for the job, including 32mm open ender, and don't forget the safe place that you stored your new gaskets.

This wasnt a rush job, and I did in 4 hrs, allowing 1 hr for total clean up & soak.

It was a refreshing reminder of why I havent been on the tools for last 10 years, and why Im not going back in a hurry

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

It was a refreshing reminder of why I havent been on the tools for last 10 years, and why Im not going back in a hurry

Back huh?

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

Back huh?

Yeah, sort of, as the 50mm lift kit doesn't help the back either, even though Im 190 cm. It was a bit sore when I was out shooting last night, on a cold night here, but its fine today.

Its just the whole thing really. Its probably hard to explain. I enjoyed getting into it, but just for the day thanks, and on my terms, in my shed, with my radio station on, etc.

Im going to check build up in my 5L Hilux engine next, even tho it doesnt have EGR. But maybe another day, not today....

[Allfour4x4 Junior Member Find all posts View Profile Close Allfour4x4]

Going in to pick up the inlet and throttle gaskets tomorrow, be interesting to see what she looks like!
Can someone tell me what size socket I need for the injectors? (I'll do them while at it) I know it's a deep reach one, but unsure of actual size