How to clean the D4D intake and EGR sytem

[Hellbound]

Has anyone found a way to clean the lower half of the manifold effectively, without taking it off the car ! I was quite happy removing bits n pieces until i got down to the lower manifold but didnt want to take off the injection pipes to take it off, got scared! haha

[Swinny]

has anyone had problems after blocking the EGR off well the plate you get from the chip it site..

[Steve9R]

A friend of mine recently told me that the primary reason that there has been carbon buildup within the EGR valve assembly is because of prolonged slow speed driving.

This has apparently been found in some cases on D4D Hiaces, where carbon has blocked the EGR valve, reducing engine power and activating the engine warning light.

On later model hiaces, the EGR programming has been changed to allow increased flow through the EGR.

Steve

[blownlux]

i think you are right about the way we drive, i drive mine hard and it had less build up than the one my cusin purchased from an old man that drove it as such my cusins hilux at 100 had the engine light come on and it was due to the build up,

[Guide1895]

Thanks mate.
That was really well done.
I have just pulled the egr off and I found my just like your photos.
Also there was heaps of wet oil down the turbo outlet and on both inlet and outlet of the intercooler.
Is that normal?
Cheers mate.

[lais817]

Hey guys, this is a question for all those who have removed the intake manifold. After doing my egr elbow etc the other month I finally worked up the courage to do the manifold, because god knows it needs it. Got all the way through to removing the cooling hoses on the EGR heat exchanger and just simply couldn't plug them well enough to stop sheet loads of coolant running out. Needless to say I quickly put it all back together and ran away after that how have you blokes plugged the coolant lines or should I just let the bit in the lines run out and go buy some more coolant from Toyota to top up?

[plaasvark]

Thanks for the write up, My 3.0 d4d Hilux have done 188000kms. Will definitely use your post to do the job. Will need to clean my '05 2.5 d4d also, it has done 240000kms. It takes a while to start, had it to a few Toyota dealers and they all said it was the fuel pick up in the diesel tank being clogged up. I had it cleaned but no difference. I'm pretty sure now it is a clogged up EGR. (if I made a few writing mistakes, please excuse me, English isn't my first language)

[Johnnyacclude]

Did this mod over the 60% of the egr was blocked
And a good thick layer of soot coated the manifold

Goes alot better after the clean wtb the egr3 cleaner

[Hellbound]

Nice one mate, i've got some egr3 to use but a little unsure how to use it ! I'm assuming you lift the lid on the airbox and spray it past the airflow meter with a nozzle and spray into the inlet tube while its running?

[CostaRicanHilux]

reporting in,
i have a 2008 hilux with 40,000 kilometers on it, it does not have the egr cooler,
I took apart the egr this weekend and found no buildup of gunk.

[2alandvan2]

Tried to get some EGR3 today and was told they are not selling it anymore because some guys blew up their motors. (Most likely mis use). They said they are releasing an EGR4 in the coming months.

[Lyle]

I cleaned out the whole intake system on the weekend on my 06 1KD 3.0l D4d (135 000k), it was about 40% blocked. I noticed the head also has the same amount of build up in it, I got what I could with a rag but I would like to clean it out a bit better. Am I right to assume that the exhaust side of the turbo will have an amount of build up on it also?

I have rang around for the Wynns "EGR 3" spray in Perth and the Wynns rep has told me it has been pulled from the shelves, but they are working on something to replace it soon. I then chased after the Liqui Moly "Breath of Fresh Air" spray, but was informed by the sales rep, that it too has been pulled of the shelves. I was told that some people were spraying too much in and creating hydraulic locks in the engine causing massive engine failure.
I was also told about Threebond "Diesel Conditioner" but it is a foaming agent. Because of this, I dont know if it can be sprayed directly into the engine while it is running. Just wondering if anyone has used this product? If it is suitable, getting my hands on some is another battle.
I also found online another product by JLM "Diesel Air Intake & EGR Cleaner", from what I found, this is not available in Australia.
I see "Power Tune" is mentioned here, Isn't is designed for petrol engines and in that case wouldnt a petrol intake cleaner do the same job?

Basically I just want to know if anyone has got their hands on a reliable product lately that will clean the intake system while running???

[Rocket55]

Just use Glitz Stainless Steel BBQ Cleaner. That's what Toyota use (saw it with my own eyes). Cheap from Bunnings and the like.

[D4DEVIL]

Just got my truck back tonight from mechanic, pulled the whole intake off and cleaned it, reassembled with new gaskets all round. First drive, it idles nicer, sounds like a diesel again, has noticeably more power and better throttle response. Would this proceedure affect how the turbo sounds or for some reason make my rattling injectors quieter?
Thanks.

[2alandvan2]

How much did the clean cost?

[Prescott]

I though i'd have ago at this today since i had nothing else to do. Very easy, when i had it apart it didn't have much carbon buildup in it at all. I cleaned it up anyway. Was still worthwhile doing.

[Your Mum]

Well if your egr valve and elbow was full of soot that means the rest of the intake system is also full to the brim. You need to pull the complete intake system off and clean it also.

[buck972]

An awesome write up very informative , Just cleaned my intake ,throttle body and egr valve and it made a difference the motor is more responsive and
more like a new hilux in response and pulls better with 140000kms on the clock ( 2008) I thought it would be a lot worse than it was the carbon build up was more wet like a dryish grease type sludge than dry carbon deposit and I would say it was about 20% blocked I will be doing the full intake manifold in the near future as now I are way more comfortable in the process ( and I have a good excuse for the to get some crows foot spanners -hello snap-on van ) I got out what I could but I think there are better benefits to be gained by doing the whole intake. I will post some pics soon, can anybody let me know if they have put a egr blankoff plate on a 08 sr D4D engine , does the cause any problems such as codes or mechanical problems ( without a chip ) ???

[Monaz]

G'day buck, mate this may not help you at all? My water pump shit itself yesterday so I replaced it today, in the process thought well may as well do the timing belt, it is due in 15000k's anyways and I didnt really want to be pulling it all apart again....BUT...while that was all off it was incrediably easy to fit up the blanking plate! Now, I do run a chip it, I do (now) have a new timing belt, have previously done the EGR clean out, but I can say that I have noticed a difference in low down to mid range power, and although its only early days no codes or warnings. I did drill a 12mm hole in it though, thats the min you need to stop the code apparently. Food for thought....oh and heaps less (almost none) smoke out the back too!

[allanj]

Did the water pump on my 05 D4D recently & will do a complete intake clean soon @ 140,000K.
My question is did anyone have problems re using the injector lines as there are some indications that they are not suitable for re use.