How to clean the D4D intake and EGR sytem

[Gipsy]

hahahahah... toyo dealers would love you if it was... lots of $$$$$$'s for them

[LocalFart]

Okay so had a crack at the 'Top End' EGR clean on the weekend.

EDIT: Thought I would add that it has 80xxx kms on the clock

Bit of a pic beforehand


You can inspect the EGR valve after removing just the intercooler.


Was a little clogged but not too bad.



After a bit of carby cleaner and some dish washing liquid.




While I was at it I thought I would give the intercooler a bit of the same treatment as it had a decent lining of oil on the inside, the black liquid was some of the degreaser after I gave it a can or two.


Anyway I thought I would share my experience.

Damo

[Talktheroo]

Please where gloves when you do this job. It's very bad for you, that black stuff. No skin contact, or little contact is the way to go.
For cleaning the intercooler (inside), carby cleaner. The outside, a pick, water and compressed air. The pick tool is for getting the bugs and feathers out. Sometimes grass and grass seed.
The Roo.

[Talktheroo]

No, not part of the scheduled servicing. But when you see it you will know that it has to be cleaned out by your clever hands. With the help of some chemicals and gloves. Plastic scrapers and sometimes 800 wet and dry sandpaper, to finish off. Please stay away from the EGR shaft with the wet and dry sandpaper.
The Roo.

[LocalFart]

Oh hey Roo, thanks for that.

but yes I used gloves.. you'd be an idiot not to the amount of black sludge you're left with is crazy.

Also it doesnt come out of pavement easy so lay some plastic or cardboard down I learnt the hard way.

[Oli146]

What gaskets are required to do the clean

[robfricke]

What gaskets are required to do the clean

I changed intake manifold, throttle body to egr valve, egr valve to 90 degree elbow, elbow to manifold, egr valve to egr cooler (if fitted) and egr cooler to engine. If you don't have an egr cooler it will be a straight pipe and id still.change the seals.

I can send you p/n for the above if needed or your local Toyota spare parts should be able to sort you out. Cost me about 50 bucks for all of them.

[LocalFart]

You don't 'need' to replace the gaskets... take it easy and be careful and as long as they aren't in bad condition they should be fine.

[TOYZX]

Bugger doin that whole job again if one leaks, for the sake of a few gaskets!

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[Talktheroo]

Bugger doin that whole job again if one leaks, for the sake of a few gaskets!

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Love it. LOL.
The Roo.

[LocalFart]

Bugger doin that whole job again if one leaks, for the sake of a few gaskets!

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Oh don't get me wrong, I'm in the same boat... that's why I had 'need' in quotes.

[Talktheroo]

If you are a commercial operator in the trades, may I suggest it's not worth the risk re-using the gaskets. Just make it part of the quote in parts or as the whole quote.
The Roo.

[Luxxy2005]

hi all.

not sure if this photo will work or not but can someone tell me what this is, and how important it is? should it be leaking at all? would it control anything to do with a fault code?

description if the photo does not work, cylindrical plastic thing with two tubes, 1 inlet to the inter cooler- 1 outlet to the inlet manifold

http://www.newhilux.net/ridethumbs/Luxx ... G_4940.JPG

http://www.newhilux.net/ridethumbs/Luxx ... G_4941.JPG

cheers

[TOYZX]

Thats the filtee for the map sensor. Doesn't look like much but can reap havoc on things!

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[Luxxy2005]

No worries, anyone know a part number

[j666eds]

Hi From the UK,

Going to have a crack at this, this weekend on my 2.5 hilux with 250,000kms on the clock. Thing is slow as shit at the moment and can sometimes be hard to start (hoping it isnt injectors) will post pics up when done.

Thanks for the good write up to follow too.

[brighty4wd]

Hi guys,
So a mate of mine had his 2008 hilux starting bad and had lost a lot of power(260k on the clock), so we started investigating and came across this forum. Freaking brilliant and many man hours reading and making notes. Ripped the intercooler off and found quite an excessive amount of build up inside the EGR housing and neck to the inlet manifold so decided that it needed to be pulled off and cleaned out properly.

Last night we got stuck into stripping it all down and have most of it all cleaned, just a few little bits to tidy up on the inlet manifold itself, BUT...... how the hell do you clean the ports out on the head without this sticky crap falling into where the valves are? Extremely worried that some of this tar gunk will fall in and not be able to be sucked out!!. This is something we cannot just leave as is as it is WAY too blocked up!! We have an industlrial Vaccum with 13mm hose taped to it to allow access into the smaller parts.

Anyway... check out these pics.

Inlet manifold 1


Inlet manifold 2


This is the gunk that came from the inlet manifold only


The ports on the head!! How the hell to I clean these out, and anthing I should be worried about apart it dropping down inside? I would estimate that this middle port is 70% blocked.

[fourby4diesel]

Vacum while scraping ports, if soot gets under valves, you will have no compression & will not start.
After cleaning, do comp test to make sure you have compression or you will be stripping & taking head off.
Fun stuff, but you should be right, vacuum!!!!

[fourby4diesel]

No worries, anyone know a part number

Of?

A guess

[fourby4diesel]

What gaskets are required to do the clean

Egr elbow to manifold is usually flaking.