EGR System coke-up

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

Hi Fellas. Anyone had trouble with EGR system fouling up the intake manifold of 1KZ-TE engines? My young fella just had the head off his and the intake manifold was really badly choked up around no.4 cylinder. He ended up having to replace the head (cracked) and shave the exhaust manifold (warped 2mm in centre when straight edged). He locked up the fan coupling as it hadn't done the business and he was fairly confident that it had contributed to the fry-up. He also blanked off the EGR system and has noticed a small improvement in power and economy.