How to clean the D4D intake and EGR sytem

[wad]

Awsome job steve, info and instuctions were top notch. Mine had between 5 and 10mm build-up in the EGR, elbow and the inlet manifold. Vehicle has travelled 78,000km.

[blownlux]

just cleaned mine took 5hrs removed intake manifold aswell, had about 40% of rear port blocked, its done 130kkm what a mess to clean.

[lais817]

just finished cleaning my EGR/intake, now I can't get the bolts that hold the valve to the manifold back in! Seems they don't fit flush with the bottom of the flange, is this because I'm doing something wrong or the way they are? I really need a bit of help guys, it's pissing me off and I'm starting to stress!

[blownlux]

loosen the exhaust gas cooler on top of the manifold, so you can getthe 2 bolts below the egr in aswell.
might help

[lais817]

loosen the exhaust gas cooler on top of the manifold, so you can getthe 2 bolts below the egr in aswell.
might help

Nevermind, I was trying with the wrong bolt all better now, and the lux feels heaps more "zippy", the amount of crap in there and it's only done 23K, pretty scary.

[Goldminer]

Just pulled mine apart, as it has done about 118k. It is as clean as a whistle compared to some of yours. I am amazed as I was prepared for the worst. It does have a fine layer of soot but that can be expected. I have only ever done long distance kays with my ute. And it is running diesel gas. Maybe thats the difference. I will spray some EGR3 in there just to be sure. I am wondering if any we can narrow down the conditions where this problem occurs. Can anyone shed some light on the type of driving they do and whether you have diesel gas or any other contributing factors.
Cheers
Wes

[bortho]

Hi guys i'm new to the forum and find this interesting. I have 76000kms on my hilux, o8 d4d and i'm thinking about cleaning mine out.
When some of you have cleaned it out and get more km's per tank, how many km's are you getting per tank?
My fuel light generally comes on about 720-750kms, how do yours go?

Regards,

Ian

[Rich]

Hi guys i'm new to the forum and find this interesting. I have 76000kms on my hilux, o8 d4d and i'm thinking about cleaning mine out.
When some of you have cleaned it out and get more km's per tank, how many km's are you getting per tank?
My fuel light generally comes on about 720-750kms, how do yours go?

Regards,

Ian

Yours is fine, My D4D fuel light comes on at around 470 Kms!

Anyway, I was just wondering if anyone has blocked off the EGR completely to stop this happening. It seems if you are running the diesel with the EGR, you are letting your engine choke on it's own crap...
Would love to clean mine out and block it off to stop it happening again.
Any bad side effects of doing this?

[bortho]

i done reading up recently about blocking them off rich, i'll be cleaning mine out and blocking it off very soon. i just picked up my chipit module and EGT from the post office and called chipit today to order the block off plate for the EGR

[bortho]

and 470km's?? that seems crazy. hope you sort something out with that

[Rich]

Yeah, I'm waiting on the local toyota dealer to get back to me. I even sent them a link to this thread!

Hopefully I will get it sorted - with the price of fuel lately!

Did you see the other thread about blocking off the EGR? I think the outcome of that is that you need a chip to do it (as you have purchased)...

[bloke&tackle]

Rich does your engine have the cold rattles?
I suspect the dodgy injector problem common to a lot of D4D engines causes bad fuel economy.
Mine is like yours...lucky to get 550Kms out of a tank.

[Rich]

I use to notice the cold rattles when I lived in NSW, but can't say I really notice them much anymore, is it possible it is not cold enough up north?

Perhaps I just use so much diesel due to all the accessories I have added (bullbar, winch, dual batteries etc) and 31" tyres. Add to that, most of my driving is around the city...

I have no doubt my EGR is choked up, as I drive conservatively and that is when the EGR operates most I think...

[Jack S]

Guys i run on 33" muddies and get about the 500k out of a tank. Not sure weather i should give mine a clean out or not....

[bortho]

Yeah, I'm waiting on the local toyota dealer to get back to me. I even sent them a link to this thread!

Hopefully I will get it sorted - with the price of fuel lately!

Did you see the other thread about blocking off the EGR? I think the outcome of that is that you need a chip to do it (as you have purchased)...

Yea, i did see that on the other thread and looks like you may need a chip to prevent an erroe code coming up if i read correctly. Just give robert from chipit a call and ask the simple question directly to him.
It would be good if you dont need the chip to run the plate.

[KTM525EXC]

I have no doubt my EGR is choked up, as I drive conservatively and that is when the EGR operates most I think...

Light throttle and light load is when the egr is open, so the more load and the more throttle input shuts the egr because in order to make power you need fresh air, so driving conservativly would cause more build up compared to if you had a heavy foot.

cheers Troy

[MADDOG]

I have no doubt my EGR is choked up, as I drive conservatively and that is when the EGR operates most I think...

Light throttle and light load is when the egr is open, so the more load and the more throttle input shuts the egr because in order to make power you need fresh air, so driving conservativly would cause more build up compared to if you had a heavy foot.

cheers Troy

Mine must be clean then.

[lais817]

I have no doubt my EGR is choked up, as I drive conservatively and that is when the EGR operates most I think...

Light throttle and light load is when the egr is open, so the more load and the more throttle input shuts the egr because in order to make power you need fresh air, so driving conservativly would cause more build up compared to if you had a heavy foot.

cheers Troy

Mine must be clean then.

You and me both

[KTM525EXC]

im hoping mine is the same as i do lots of country / hills driving

[freddy10_9]

i done reading up recently about blocking them off rich, i'll be cleaning mine out and blocking it off very soon. i just picked up my chipit module and EGT from the post office and called chipit today to order the block off plate for the EGR

Has anyone blocked the EGR off at the head without a chipit chip fitted and not had it throw a code and go into limp mode