How to clean the D4D intake and EGR sytem

[StevenS]

Mines an 05 and it had a little bit of build up, but nowhere near as much as some others have reported on here.

I get low 10s per 100km on mine, single cab diesel, with no load except my fat arse

[dute]

Well I got time to have a look at mine today and this is what I found well not realy I forgot to take photos so I just went thru the thread and this photo has about the same amount of crap I found in mine .



Put it all back together and went for a test drive . . . does go a bit better now

What I forgot to post is that my ute is a 09/2007 SR with 67000k's on it running a Steinbauer chip and a boost control wound up a little

So a week after cleaning it I have seen a improvement in the fuel economy but that will go out the window as soon as I put my play tyres back on

[pjtaylor03]

I am going to get this done. I have a mate 2 doors up who is a mechanic if i get into trouble. But is it worthwhile having getting all the new gaskets in case they get damaged pulling it apart or should it be right to reuse the same ones.
Paul

[axeten]

Gaskets will be fine if you're careful.
From memory, they were all metal gaskets anyway

[fourby4diesel]

You guys have the best website sharing info for each other it's growse.
I have been pm'd about use of Subaru upper engine cleaner so I thought I will provide the diesel version
You can get same stuff from ford dealers it will help keeping the whole system clean.

 
To Whom It May Concern,
 
Subaru or Ford Upper Engine Cleaner can be used in both Diesel and Gasoline engines and will perform the same function in both systems with no ill effects. Breaking down carbon deposits helps preventing the Particulate Diesel Filter from clogging up.
 
The application for Diesel engines is as follows:
 
1. Start engine
2. Wait for 5 to 10 minutes. Warming up process.
3. Stop engine.
4. Remove air cleaner.
5. Remove Fuel Filter Hose and keep idling until no more diesel fuel.
6. Pour entire Upper Engine Cleaner into intake manifold by activating starter motor or by cranking under no fuel condition.
Warning 1.  Do not use Upper Engine Cleaner on the Toyota IC Engine (Toyota  Corolla, Sprinter, Carina engine or so on).

Warning  2. Pour Upper Engine Cleaner by cranking. Water hammer phenomenon may be caused by spraying Upper Engine Cleaner while engine is running (by not cranking) due to smaller cylinder capacity on diesel engine.

7. Wait for 5-10 minutes after spraying entire Upper Engine Cleaner content allowing Upper Engine Cleaner enough time to penetrate.
8. Start engine again, keep idling engine high until no more smoke comes out from exhausting pipe.
9. Do idling adjustment if necessary.  Finished.
 

[ibm450]

cheers

[hoddy7]

Hey, had my hilux for 3 weeks now and this seemed like a good place to start on the engine, it's done 110,000 and was abt the same as the last photo, awesome write up, thanks

[Kris]

I cleaned mine today. it's an '07 model with 175500kms on the clock. it had probably 40% blockage. Once it was all together I took it for a drive and the engine light was on and it was in limp mode. Came back, took the intercooler off and found a connection that had not seated properly. Took if for another drive and the engine light is still on but it is not in limp mode now.
Not sure why the light is on, might take it to toyota for its next service and get them to check it out.

Kris.

[phillshilux]

[classic_salt_water76]

My engine light is on!!! went in and it was the EGR valve warning costing me $360 to get her cleaned up at Toyota in Port Macquarie. Good thred guys

[lais817]

My engine light is on!!! went in and it was the EGR valve warning costing me $360 to get her cleaned up at Toyota in Port Macquarie. Good thred guys

Did they say what was wrong with the EGR valve mate? Or what they did to fix it?

[Kris]

After about 60km the engine light is off in mine and all appears well now.
Kris.

[ryanone]

its great to see some people with such vast knowledge, i gave this a shot and worked perfectly, although my best mate works at toyota in perth, there is 2 hoses running off the back of the EGR that a only about th diameter of 3 mm which have one way valves on it if you stick 2 small ball bearings into the hoses it permanently blocks off the EGR causing no more soot, increased power and more emissions depending on your states law it can be big penalties, but the hoses are hidden and its hard to explain like steve has done but it works , my hilux has 196 000 on it and still goes strong, its well worth a shot if you know the technical side of things ,


the law will never find the hoses from being blocked and neither will your pit inspections if your car were to be defected, thought for you all.'

cheers

[Skitz-4x4]

Interested in more info about this ^^ wouldn't the ecu throw a fault code sensing no airflow through the egr? Cleaned my Egr valve out on the weekend took 3 hours all up and was a very simple process..Hardest part was cleaning all the soot/gunk out.. (instructions are very detailed) so i applaude you for the main post.. my lux is an 07'' with 155,000 km and was a good 40% blocked.. definatley noticed smoother idle and low down torque increase.. will be blocking the valve later on once i fit a chip to counteract the fault code.. don't like the idea of smelly poo carbon mixing with fresh air in the engine..

cheers scott

[Hellbound]

Did u go as far as taking the lower inlet manifold off ?

[lais817]

I've taken the inlet manifold off Hellbound, wasn't a great deal of blockage in it, maybe 3-5mm of sooty shit coating all the surfaces, that was about it. Wasn't too hard to do, took me a few hours, and just cleaned the lot up with carby cleaner.

[Hellbound]

Ah sweet mate well done, any tips on getting the injector pipes off to get it out - do they need to be de-pressurised or anything like that, and is the inlet manifold gasket reusable?

[lais817]

Ah sweet mate well done, any tips on getting the injector pipes off to get it out - do they need to be de-pressurised or anything like that, and is the inlet manifold gasket reusable?

I didn't have to depressure the pipes but I had some safety specs on just in case, as suggested by the threadstarter. as for getting them out, if you have a crow foot spanner your laughing, piece of piss. the manifold gasket is steel so if your careful getting it off you can reuse it, but if I had the cash I'd probably replace it for piece of mind

[Hellbound]

Thanks mate much appreciated, cheers

[vortexheli]

has anybody got dimensions for a EGR blanking plate? or even just the bolt centres? I want to make one up,
Cheers