Cleaning the intercooler

Submitted: Tuesday, Jan 27, 2009 at 16:15
ThreadID: 65459 Views:6235 Replies:4 FollowUps:10
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Hi guys,

I just thought I would give a heads up on my Australia days celebrations. On Sunday, I had a good old fashion beef feast on the BBQ where I spoke with a couple of fellow Patrol owners. Somehow we decided to clean our intercoolers on the public holiday because with a couple of rums under the belt and we all felt pretty mechanical. The following day I actually got up early and ripped off the intercooler and associated piping and gave it a clean with some diluted CT-14. The first flush wasn't that impressive, but after a shake for several minute with the next batch, well it was a black soup. After 6 flushes it was clean but wow, it was certainly worth the effort. My mate with a after market Turbo and intercooler on his 4.2 said he could even gain access to his turbo vains and cleaned them with a cotton bud and he said his Patrol took off like it was chipped. Not so for me, but I am looking forward to see if my economy will increase. Worth the effort guys.

Cheers
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Reply By: Member - Malcolm (Townsville) - Tuesday, Jan 27, 2009 at 17:00

Tuesday, Jan 27, 2009 at 17:00
Hi Dave

As part of the rebuild of my ZD30 I cleaned the IC and hoses with Degreaser from SC (4 for $5 on special), used a couple of cans making sure everything had a good soak before blasting it out. Then I cleaned the MAF with CRC MAF Cleaner (which IMHO is only electrical circuit board cleaner).

Unfortunately I don't have much to compare my efforts to but judging by the crap that I got out (keeping in mind I blew a piston and all that diesel/oil would have gone through the system).

I would recommend it as maybe 50-100K service requirement.

Malcolm
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Follow Up By: Dave & Shelley (NT) - Tuesday, Jan 27, 2009 at 20:03

Tuesday, Jan 27, 2009 at 20:03
Hi Malcolm,

Hope I never have a project like yours!!!!!. I am certainly keen to look at the MAF before my next big trip. I was amazed with the amount of crap in the "clean" air system. I am also looking at gaining access to the turbo and giving that a clean. My MAF must be clagged up somewhat since the rest of the system is looking average. I have had the Patrol since new and since I don't have kids, this is my substitute!!! Hope my ZD doesn't come a cropper!!>

Cheers
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Follow Up By: Member - Malcolm (Townsville) - Wednesday, Jan 28, 2009 at 01:02

Wednesday, Jan 28, 2009 at 01:02
Hi Dave

The "project" was just a matter of sticking with it. Once I got over the initial shock. Must admit some days I just couldn't even look at it - suppose that's why it took me 3 months.

This one was a one-owner, serviced by the 'mechanic' owner every 10K. His wife used it to take the kids to/from a country school.

The history of ZD30 "blowups" points to the vehicle under load (e.g. towing caravan) on highway at 100-110kmh. Mine certainly fitted that scenario.

Do you have EGT and boost gauges fitted? Most of the knowledgebases I have read certainly suggest to do it. I am in the process of installing mine. When the MAF gets oily it sends the wrong messages to the ECU which can result in over-boosting, which, in turn, can result in piston failures. That's how I understand the problem.

You need a special security key to remove the MAF sensor. I did mine by removing the 4 screws on the air intake just past the MAF sensor, unclip the air cleaner, remove and spray inside to the MAF contacts.

Malcolm
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Reply By: Member - Bevan (QLD) - Tuesday, Jan 27, 2009 at 17:14

Tuesday, Jan 27, 2009 at 17:14
how many Km's had you done befor you did this clean ?
AnswerID: 346188

Follow Up By: Dave & Shelley (NT) - Tuesday, Jan 27, 2009 at 19:54

Tuesday, Jan 27, 2009 at 19:54
Hi mate,

I have done 81297K. I have had the Patrol serviced every 10,000, and I have spent the extra after big trips like the CSR on major services. I don't use much oil, but there was a bit in that intercooler!!!! I think a catch can is the next project after this.

Cheers
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Follow Up By: Member - Glenn D (NSW) - Tuesday, Jan 27, 2009 at 20:50

Tuesday, Jan 27, 2009 at 20:50
Dave & Shelly ,

Everyone I talk to is doing 5k services on the 3.0td , pretty sure the owners manual says something like 10k or 5k under extreme conditions , I think Oz is considered extreme !

Cheap insurance ?

Glenn.
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Follow Up By: Dave & Shelley (NT) - Tuesday, Jan 27, 2009 at 21:12

Tuesday, Jan 27, 2009 at 21:12
Hi Glenn,

I do the 5K service myself. Can't bear paying someone to do that easy service and lose the car for a day. I have been using CASTROL MAGNETIC 10W40 and the oil is pretty clean when changed. What about yourself????
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FollowupID: 614187

Follow Up By: Member - Glenn D (NSW) - Tuesday, Jan 27, 2009 at 23:06

Tuesday, Jan 27, 2009 at 23:06
Nissan have semi - synth oil , B3005-10W40PK part number for 5ltr . Specificley for the 3.0td.

Would like to say it isnt a big deal for you in a later model Patrol , but do a search and see a few have detonated !

Glenn.

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FollowupID: 614225

Follow Up By: Member - Bevan (QLD) - Wednesday, Jan 28, 2009 at 14:23

Wednesday, Jan 28, 2009 at 14:23
i have done 220,000km on mine. i brought it when it had 195,000km and dont know if it has been flushed befor. mine is a 2.8 and getting abit sluggish. what is the flushing stuff ca;;ed, or should i just use any degreaser ?
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Follow Up By: Member - Malcolm (Townsville) - Wednesday, Jan 28, 2009 at 14:53

Wednesday, Jan 28, 2009 at 14:53
Bevan

I used those red degreaser cans from SC. Spray on, leave a few minutes and flush off with water.

Malcolm
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Follow Up By: Dave & Shelley (NT) - Wednesday, Jan 28, 2009 at 20:46

Wednesday, Jan 28, 2009 at 20:46
Hi Bevan,


I used CT-14 as it was non-flammable. It worked pretty well. I avoided the flammable stuff because I thought when I started the engine next it might have overrevved.

Cheers
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Reply By: Trevor R (QLD) - Tuesday, Jan 27, 2009 at 21:13

Tuesday, Jan 27, 2009 at 21:13
I have been putting this job off for ages on mine as I put the plumbing in on mine and it was a b@$tard of a job to squeeze them through a couple of spots and don't want to go through it again but I know I should. My pipes are only 380000km new so I reckon they are due for a flush, what do you reckon? You may just have given me the push I needed.

Hope the economy gets better as a result of your efforts.
Trevor.
AnswerID: 346220

Follow Up By: Dave & Shelley (NT) - Tuesday, Jan 27, 2009 at 21:20

Tuesday, Jan 27, 2009 at 21:20
Hi Trev,

Well, 380,000KM, um yeah, you might need to "give the pipes a flush" so to speak. Would be very very interested to see how much black rubbish comes out of your intercooler and pipes. I was actually rather surprise at how much came out of mine since I spoil the hell out of the young girl. It was a half day job from start to finish. I would only use bio-degreaser as the flammable stuff might give you a little rev when you start her up!!!!.

Cheers
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Reply By: awill4x4 - Wednesday, Jan 28, 2009 at 20:05

Wednesday, Jan 28, 2009 at 20:05
It's probably a better thing that the intercooler is checked sooner rather than later. The pic below shows what can happen when the intercooler cover rubs against the cores. This isn't an isolated occurrence either, I've now heard of 3 people with identical problems.
The answer appears to be using some washers to space the cover up so it no longer rubs against the core.
Regards Andrew.
AnswerID: 346418

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