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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, 08:21 AM.

  • #2
    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.

    Comment


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

      Comment


      • #4
        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

        Comment


        • #5
          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.

          Comment


          • #6
            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.

            Comment


            • #7
              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.

              Comment


              • #8
                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.

                Comment


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

                  Comment


                  • #10
                    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.

                    Comment


                    • #11
                      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

                      Comment


                      • #12
                        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.

                        Comment


                        • #13
                          Originally posted by Anth120playdo View Post
                          Disagree,
                          Hilux & 120 Prado are completely different to 150.

                          Hilux is the easiest.

                          No need to remove wipers on vehicles with top mount intercooler.
                          I did mine without having to remove any sort of wiper related stuff. I may be mistaken but that hilux forum post is on a '08 hilux which i think is the 1KD? All the photos in the post look exactly the same as what I came across. Did I miss something?

                          Comment


                          • #14
                            Originally posted by JimmyC View Post
                            I did mine without having to remove any sort of wiper related stuff. I may be mistaken but that hilux forum post is on a '08 hilux which i think is the 1KD? All the photos in the post look exactly the same as what I came across. Did I miss something?
                            Sure you can do anything, but it would have been very difficult. Especially to get to the 3x 12mm bolts holding the elbow. Try to do things the easiest way.

                            Same engine, different vehicle.
                            Different engine mounting position.
                            Different cowl around wipers.
                            Toyota procedure by the book is correct.
                            Working around it is not the best way.

                            So no not exactly the same.

                            Cheers.

                            Comment


                            • #15
                              I will back up Anthony's words of wisdom. On advice & his supply of Denso Injectors & pipes, my 2009 120 IKD was given the full clean treatment including Head clean & valve reseat and 7mm EGR plate. (#3 injector value out).

                              I now only use (for Qld temps) Penrite HPR 15, change oil & Ryco filter every 7,500Kms including oil flush. Also doing the Inlet clean with Liqui-Moly Diesel intake Decarb, every second oil change.

                              Prado has done another 35K, runs like a rabbit & purrs like a kitten. Dipstick oil only gets a slight grey tinge by time next oil change /service due.

                              Some may think the above is over servicing - but I sleep well at night

                              Since Anth's visit here my Prado only drinks at BP.

                              All the above thanks to Anth's knowledge & sound advice.

                              Comment

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