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2011 KD1 150 series EGR and intake clean gone wrong

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  • 2011 KD1 150 series EGR and intake clean gone wrong

    Hi All,

    recently servicing my 2011 Prado and notice an oil drip from the 2 inch hose between the throttle body and intercooler pipe
    instead of just tightening up the hose clamp and being done with it I decided to investigate, previous to this point the car was running fine
    also at this point id like to add I'm a mechanical fitter by trade but only tinker with my own cars, I'm used to much bigger equipment

    I removed the intercooler pipe and could see a pool of oil in the hose, my immediate thought was the turbo oil seals had where on the way out
    I removed the turbo pipes and inspected the turbo and intercool, all oil free and reasonably clean

    a bit of googling told me that oil pooling here can be from the EGR system so I investigated further, removing each bit until just the manifold, EGR cooler and fuel lines where left
    everything was looking pretty dirty inside and I could see the manifold was caked in sludge at this point I decided its only a few more bolts and I still had half a case of corona so why not go the whole way and remove the manifold and clean it out, it looked like every one else describes about 25% blocked if not more especially towards cylinder 1 and 2

    to get to this point if you've done it you know it involves removing a load of vacuum controls/hoses etc

    any way it all went back together reasonably easy and no real drama, to my shock it even started after pumping the fuel primer a few times

    my problem i have now is that on start up its billowing white/greyish smoke from the exaust, my initial thought was its just burning of the degreaser I used on the intake and EGR cooler etc
    once it got to normal temp the smoke stopped hooray! a quick spin around the block and the smoke was back, boooo, turned it off and went to bed

    next day started it up, billowing smoke that then stopped at normal engine temp, quick spin down the highway and the smoke was gone, when I started to slow to a stop i could feel the engine shuddering as if it was miss firing then the throttle became unresponsive for a little bit before returning to normal

    I now have an intermittent billowing white/greyish smoke and what feels like a misfire/staling engine

    I can only think I've gone wrong some where with a vacuum line as everything else can only go to one spot

    any input or ideas from any one else that's been down this path would be super appreciated or even a link to a decent vacuum diagram or ways to test things are functioning as they should, I'm not getting any fault codes or alarms, also while I had it in bits I changed the glow plugs as knowing my luck they wold need replacing next week if I didnt

    Cheers in advance

    Aaron

  • #2
    The oil in the intercooler hose actually gets there via the engine breather hose on the left side of the engine if you are looking from the front of the engine bay. The black soot gets in via the EGR from the exhaust. The oil and the soot mix to form the sludge that you found. The white smoke sounds like oil burning. Has the breather been correctly reinstalled? Any smoke come out of the oil filler cap if you remove it?
    [B]Steve[/B]

    2010 Silver GXL Prado 150, D4D Auto, with a few non standard bits

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