how to remove 1KZ intercooler and clean throttle body

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

Well, pulling it down, but I'm going to stop here!
Bit of weepage coming from somewhere around the outside of the throttle body, but clean as a whistle inside, starting to wonder whether or not to do the injectors now? Car has 170,000 klm's

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

You would think your egr had been blocked off earlier

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

Nope! owned her from new - 2000 model. Well there's a point, did the early ones still have EGR? (Showing my mechanical skills here)
To be honest I took this shot then retired inside, it's getting cold in the shed! and I didn't even look for the EGR.

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

Thanks. Now don't take this the wrong way as I am not doubting the advice on here, just trying to understand. If it is the EGR, then how come there is black crud on the top of the throttle butterfly, as this is before the EGR in the scheme of things. I am a tad confused.
Cheers...Wayne

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

Thanks. Now don't take this the wrong way as I am not doubting the advice on here, just trying to understand. If it is the EGR, then how come there is black crud on the top of the throttle butterfly, as this is before the EGR in the scheme of things. I am a tad confused.
Cheers...Wayne

I think you will find that that buildup is from the PCV system which hovers inside the inlet hoses and throttle body after the motor is switched off.
This also finds it's way to the MAF and builds up, as well as the air filter.
Carbon and soot will be inside the inlet manifold as the EGR only opens when the engine is cruising or at idle, hence, one side of the throttle body butterfly gets covered in it.
The turbo pressurises the inlet manifold and can also cause buildup.
So as I have said before somewhere, block the EGR, fit a catch can after cleaning everything out and there will be much less buildup, if any.
Cheers, The ferret.

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

Well, pulling it down, but I'm going to stop here!
Bit of weepage coming from somewhere around the outside of the throttle body, but clean as a whistle inside, starting to wonder whether or not to do the injectors now? Car has 170,000 klm's

The oil I would say is coming from the PCV.

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

Well I have never really taken much notice of fuel consumption in my Prado. I find there are so many variables when trying to run out 180L, and when I go on long runs its usually towing camper, rack sack, offroad or gravel etc etc.

Took Prado on first decent trip since manifold clean to Walpole, Nornalup, where it was just the 5 of us with some clothes and food for a few days away.

The Prado did
840 kms (I allowed for 5% speedo error on 265/70/17 BFGs as per GPS)
95L Fuel, filled by me both times
Ave: 11.4L/100kms
Not bad for an old oiler with 50mm lift, oversize tyres, and plenty of other accessories.

Its a winding hilly road through Nannup, Pemberton and went via Northcliffe. Not much over 100kmh, and lots of sharp corners and hills to slow us down.
My son drove some of the way on his L Plates, and we only did about 25kms of 4x4 through wet heavy sand West of Mandalay Beach.

So I am thinking the economy is better, and it does feel to be slightly more responsive when calling for a bit of help when overtaking. Seemed to be a bit smoother through the gears too.

This really is a must have job for 1KZ owners with EGR.
Just dont forget to hook up all the EGR hoses correctly......

[Bidla Member Find all posts View Profile Close Bidla]

The question was asked earlier in this thread if this dismantle and clean has been required or done on a 1KD but I can't see where anyone has responded to it so I'll ask the question again.

[pete8205 Member Find all posts View Profile Close pete8205]

I cleaned out my d4d today (well tried anyway) car has done 100000k
after reading this thread i thought I'd have a look and found to remove and clean on the d4d to be far from user friendly and exspensive
I did it with my mechanic (not diesel) and alot of time on the phone to toyota and diesal mechanics for advice
removal of intercooler to access throttle body easy
egr joins in just after there was 15mm thick buildup
to remove manifold there are fuel lines that need to be removed which are single use so if removed bin it and fit new ones at $150 x 4 ouch
I didn't block of the egr as the gaskets I needed from toyota was a 4 day wait
after a few choice words after seeing the buildup inside and looking at $600 plus dollars
we made a few more phone calls and was told to try Three Bond Engine Conditioner for diesel
not easy to find got some from penrith diesel, 2 cans bout $50
following the instructions on the can we left the intercooler of and sprayed directly into the throtle body we used both cans
all I can say is wow it all looks brand new it seems to disolve it
put back together and went for a drive well its worth the effort the engine seems to have come to life it revs freely and has also stopped blowing black smoke
I will be putting a can of this through at every service from now on
as for fuel economy the fill up 2 day ago gave 11.4l per 100 driving around town when I fill up in a couple weeks I'll post what it is to see if there an improvement

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

Yeah, block the EGR when ya can, that way she'll stay clean.
Cheers, Ferret.

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

Bursons sell the Threebond Engine Conditioner for diesel engines. $17 a can and comes with a flexible nozzle. Got 3 cans this morning from Bursons at Virginia. Will give it a go tonight when I've got someone to operate the accelerator pedal for me.

[Prado BB Advanced Member Find all posts View Profile Close Prado BB]

Pete, did you drain and replace the engine oil? My mechanic recommends to dump the oil after you use this stuff.

[pete8205 Member Find all posts View Profile Close pete8205]

yeah i'll block of the egr another time I need to fit my winch before I play with that again

$17 a bottle not bad I can't remmeber exact cost I was just happy to get it and didn't count the change

No one mentioned to change the oil after doing it, I did the oil and filter before doing this so I hope not
I don't think it would affect the engine oil as it is on the air supply and should be burnt off whilst running however I will keep and eye on it to see if any noticable changes

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

Changing the oil is advised as some of the soot from the intake will end up in the oil as it will be carried through with blow by gas. I'm pretty sure most gas installers recommend an oil change 500 to 1000km after a conversion as the LPG cleans the intake in the same way but slower.

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

i haven't worked on the intake of a D4D, so i can't completely say it good or bad, but anything with an intake
could benefit from a clean.
Pete's reply has good information.