How to clean the D4D intake and EGR sytem

[KevR]

Thanks TOYZX I took your advice.
One thing I noticed that was interesting was that the back port on the head closest to the fire wall was the oiliest and they gradually got dryer and more sooty towards the front of the motor. Also the butterfly in the intake manifold for the back port was bent or had a kink that stopped it from totally closing the next butterfly seemed very slightly bent and it's port was the dirtiest with a mix of oil and soot. The last two butterflies were straight and those ports were dry and sooty. Has anyone else noticed this with theirs , mine is a 2012.
Cheers Kev

[Talktheroo]

You won't be disappointed, Kev.
HPD catch can with it's permanent filter system keeps the oil mist out of the turbo and intercooler internals.
The Roo.

[martynvella]

What does that butterfly in the intake actually do, what's it there for?

[TOYZX]

They are the swirl control valves. They are supposed help with bottom end torque up to around 2000rpm. A lot of performance cars have them and a lot of people modifying these cars take them out because they tend to rattle like they do in the hilux! Bmw ones are known to break off and go through the engine!

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[Johnny 5]

Hi all,

First time posting...

I have a prado 120 2008, with the 1kd engine (turbo diesel). I followed the instructions on the first post, dismantled everything, cleaned all the gunk that I could and put everything back. (please note that I did not open the inlet manifold (....?) to get to which you need to undo the fuel lines, but just did a clean as much as I could).

Once everything was put back, I started it up. Took a bit of cranking to start. But since then no problems.

The problem is that there is a fair bit higher turbo whine on certain revs (1800-2200 or so). Not sure if this is normal... it seems a bit excessive. Is there something that I would have done wrong? Is there a possibility of a leak? Or maybe I dropped some of the gunk the inlet manifold or something?

Please advise, I know this is an old thread but I would like to make sure if I have created further problems for myself.

Thanks in advance guys... I know this is an old thread.

[TOYZX]

Just go back over everything man. Could be just breathing better or maybe ya left an intercooler hkse clamp loose and its leaking a little boost. If it's running fine and theres no engine lights then I wouldn't be to concerned.

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[Burb122]

Guys. Just did mine. EGR assembly was chock full. But cant do the intake just yet. It's chock too. Will just cleaning the EGR be of any use buy itself? It was very gunked up.

[Johnny 5]

Thanks for your response Toyzx. Will check again. Hopefully all is good.

[Burb122]

See most post above. It makes no difference in power or torque cleaning only just the EGR assembly. Not noticeably in my case anyway To achieve this the intake would need cleaning to. I would say it's too late to make a difference overall. Because the engine block is always going to the built up restriction point. Unless you clean the block. Still better out than in I guess.

[apSlain]

Hi all, quick one. Can a blocked/stuck EGR be the cause of black smoke and higher fuel consumption?

I have done all the usual maintenance items to eradicate the smoke (it's a mild amount hence not getting a mechanic involved) but it still persists. I'm thinking it's the EGR as my EGR Lift Sensor Volt % is rarely within 15 of the Target EGR Position. I had the EGR and Intake Manifold cleaned out last year though.

For example, my diagnostics last year had my EGR within range whereas the diagnostic I ran last month and tonight were way out.

[JChilds]

I have taken off and cleaned the top half ( to the bottom elbow)
Would liquimolly be worth looking at for bottom half?

https://www.youtube.com/watch?v=3agltbN4C7M

no.. i dont work for them.. no i haven't uesd it.. Just wondering if anyone has.. or if anyone things it would work, as egr3/4 is so hard to get.

edit: and.. Should i be doing this at the start of the egr like they said? They dont mention turbo vehicles... Doing this would bypass the turbo while you do it.. wouldn't that throw fault codes?

[TOYZX]

Probably depends on how bad it is. Ive never been a fan of these sprays as all that crap going thru the engine does nothing but harm to valve seats and cylinder bores! As part of regular maintenance then yeah maybe but as for already heavily clogges up engines I so no. Nothing beats a good strip down and clean!

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[Johnny 5]

Hi Toyzx,

Just wanted to update regarding my issue with the excess turbo whine (more of a whistle). Upon your advise, I went over everything again, made sure I had put all plugs back in, all hoses connected, all nuts n bolts tightened... and I found one that was a little loose. Tightened that and made sure all the others were tight enough. Took it for a test drive and viola, no excess whine/whistle.

I would like to thank you again Toyzx for the motivation to go over it again. Hope this might help some one else as well.

Regards,

Johnny 5

[Burb122]

Good to hear you got it sorted. Do you remember which connector was a little loose?

[TOYZX]

Glad ya sorted it man!! Thats what were all here for!

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[Bambi]

Just did mine the other day, did the inlet manifold too, wasn't too bad considering it's got 105k on the clock. Seems to be running better now, but it does have more and loudee rattle which I can hear even at 110km/h.

When putting it all back together I missed two plugs, one was for the fuel rail which I took off for a bit more working space for something (can't remember). Started the car and thought it was going to blow up, then saw the plug. Another one I missed was for on the drivers side of the throttle body.

[KevR]

Hey Bambi
I recon mine got rattlier too, maybe the deposits keep it less metal on metal. Did you notice some of the butterflies in the intake were slightly bent?

[Bambi]

Yeah not too sure, but I was hoping cleaning it would quieten it down a fraction haha. My first diesel and first hilux, I'm still getting used to how noisy they are. Has me freaking out at every rattle and bump I hear.

Nah all my butterflies looked pretty straight man. I didn't exactly have a close look at them, but nothing looked out of shape or odd or anything.

[Gumby22]

Awesome post Steve.
Cheers you have definitely saved me some $$.
My Hilux has done almost 210000 and just cleaned it out as it was full of carbon and oily soot. Running great now.

[vindecent]

A phenomenal thread!

But as someone who is not exactly mechanically savvy and lacking some of the required tools-
Is there anyone in Melbourne with plenty of experience keen to help clean out a 2007 hilux?

Happy to pay cash. Can come to you or do at my place (inner south/east side) Cheers