LC 100 sludge.

Submitted: Thursday, Apr 01, 2010 at 17:40
ThreadID: 77376 Views:8077 Replies:9 FollowUps:2
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Hi All
This is my first submission to the forum after many years or looking, learning, laughing and lamenting. Thanks to all those contributors.
Now to the serious stuff. I have a 2002 model 100 series factory standard 1HD-FTE Turbo'd Intercooled GXL with snorkle.
It has travelled 300,000 Klms mostly highway stuff (60%). Some stop start city stuff(30%). Some heavy going (10%). The oil I use is Castrol diesel 15w40. Changed at 10,000k intervals. The vehicle has nearly always been run to working temperature before shutting down. It uses no oil. It starts very easily. It blows no unburned fuel smoke. It idles very smoothly. It pulls like it should. It drinks 10% more fuel now than it did at 100,000ks.
I decided to shout it an injector service but upon removal of the inlet manifold I discovered a fair lining of sludge in the manifold(2-3mm thick). It is clean under the top end cover and around the cam and valve springs i.e. no sludge.
My question to the group is; How and why did this sludge build up happen and has any one had a similar experience?
Thanks in advance
Dave
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Reply By: Mikelb - Thursday, Apr 01, 2010 at 17:55

Thursday, Apr 01, 2010 at 17:55
David
Have just found out about this problem. I sold my 3 litre Jackaroo diesel at 195000k. The new owner complained about black smoke at about 250000k and took the vehicle to a diesel specialist. A new turbo was fitted. No difference and the old turbo sent elsewhere to be checked and measured. Nothing wrong with it. The vehicle was returned with loud complaints to the company that fitted the new turbo. The inlet manifold was removed and had about 5 mm of sludge build up. The manifold was soaked in a bath overnight the cleaned thoroughly. Problem solved and no more smoke. Another diesel mechanic stated at each service he ran some sort of cleaner through the intake manifold to stop the build up. He said that this build up was a common problem with common rail diesels.

Mike
AnswerID: 411312

Reply By: Notso - Thursday, Apr 01, 2010 at 18:00

Thursday, Apr 01, 2010 at 18:00
The diesel vehicles with EGR all seem to have this problem.

Nissan patrol 3.00, Triton 3.2 litre are two others that I know of.

I have the Triton but so far no problem with it but a lot of other owners have. Mitsubishi bought out a fix for it but all that did was move one of the outlet pipes for a sensor that was blocking up.



AnswerID: 411316

Reply By: dbish - Thursday, Apr 01, 2010 at 18:18

Thursday, Apr 01, 2010 at 18:18
David its also a problem with petrol motors mainly from Positive Crank Ventilation systems sucking in oily fumes from crankcase. Remove a cylinder head on any vehicle thats done a lot of Ks & the inlet valves & manifold will be coated in it. Subaru had a pressure pack of cleaner to spray in the inlet on there EFI moters at each service. Daryl
AnswerID: 411318

Reply By: Member - John - Thursday, Apr 01, 2010 at 18:59

Thursday, Apr 01, 2010 at 18:59
G'day, lucky you found it before it blocked completely as a mates did, it is build up from the EGR system, blank it off, no more problems............
John

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AnswerID: 411324

Follow Up By: Member - DOZER- Thursday, Apr 01, 2010 at 19:06

Thursday, Apr 01, 2010 at 19:06
Its nothing to worry about...there can be a few places it comes from, but the most likely is the tappet cover breather, between turbo and air filter, is subject to terrific vacuum when on boost, this gets worse if the filter is partially clogged.....the oil vapour is sucked into the turbo and out through the motor inlet....you can prove this by putting longer hoses on and running them both into a juice container with some steel wool in the bottom of the container. It will catch oil.
Andrew
b4 you bag me out, walk a mile in my shoes, then your a mile away and have my shoes :)

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FollowupID: 681406

Reply By: Member - Phil G (SA) - Thursday, Apr 01, 2010 at 22:56

Thursday, Apr 01, 2010 at 22:56
Yep, happens to all the 1HD-FTE's. Caused by the EGR. At 80,000k I cleaned my intake out and disabled the EGR - no more carbon in the intake since. At 150,000 my catalytic converter was blocked with carbon so I've just fitted a 3" exhaust to fix that problem - huge improvement since. My suggestion is that you do the same.

Read all about it here:
http://www.lcool.org/technical/70_series/egr_vent/vent.htm

Cheers
Phil
AnswerID: 411360

Reply By: dublediff - Thursday, Apr 01, 2010 at 22:56

Thursday, Apr 01, 2010 at 22:56
The EGR is the problem, with the high pressures in the crankcase due to turbo there is more oil fuming inside the crankcase. It is vented through the intake system via the EGR. An oil catchcan is the answer. Very simple as stated above with a 'jam tim' or similar but there are some professionally manufactured ones in the market if you don't like the idea of an IXL sticker displayed in your engine bay....lol...cheers Eric.
AnswerID: 411361

Reply By: Member - Andrew L (QLD) - Friday, Apr 02, 2010 at 13:45

Friday, Apr 02, 2010 at 13:45
Is a common problem with EGR sustems and positive presure in crankcases from the use of turbo's.

Here's my easy and cheap fix.


Sports aluminium rink container..-$10




add bras steel wool approx 50% to help condense the crancase vapour


brass gas thread fittings with R/H for crankcase breather hose, and support bracket


chassis mount bracket


fitted and running terrific for the last 3 or so years, I get about 10-15 mls of oil every 10000km or so, and a damn sight cleaner inlet system.
AnswerID: 411409

Follow Up By: Member - Andrew L (QLD) - Friday, Apr 02, 2010 at 13:48

Friday, Apr 02, 2010 at 13:48
This setup has the capacity for a larger diesel, unlike the cheap oil catch cans you buy from Supercheap etc, they do not have the volume and hose internal diametres to be effective for anything more than a Morris.


Where's an edit function for poster's...?
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FollowupID: 681487

Reply By: dbish - Friday, Apr 02, 2010 at 15:38

Friday, Apr 02, 2010 at 15:38
Andrew thats what Id call avery well thaught out & profesional looking setup. Daryl
AnswerID: 411417

Reply By: Member - David C (NSW) - Sunday, Apr 04, 2010 at 12:31

Sunday, Apr 04, 2010 at 12:31
Hi all
Sorry its taken a while to reply to the forum. I've had my own personal dramas to deal with.
Thanks to those offering advice especially the link to LCOOL and the great pics complete with pool table/work bench. (Thanks Andrew)
It looks like an oil catch can is the go. Another job in the round toit tray.
Until next time
Travel safe
Dave
AnswerID: 411608

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