100 SERIES 4.2TD EGR GUNK

This build up post the EGR valve is a common problem/issue with all engine that have this emission control system (which is nowadays pretty much all engines). If you go to the various forums you will find that lots of folks are fitting EGR blanking plates to try and stop this build-up. Not entirely legal mind you as it is "interfering" with emission control but it sure does work. I have fitted a thin piece of high grade stainless steel to blank the EGR in my D40 and it seems to be doing the trick for me.

I have heard of cases where lesser quality plates have deteriorated and a hole has blown through but don't have first hand experience of this. I also believe that the ECU on some of the more recent common rail diesels will sense when the EGR is blocked and go into limp mode. With the cruiser it might be worthwhile going onto LCOOL forum and do a search.

Blue,
4.5 V8 diesel engine at around 20,000 Km. This engine had done around 20,000 km but the hours and revs it worked would have worked out about 90,000 km.

This is what the intake manifold looked like.

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RA.

Yep, happens to all diesels with EGR. I corrected the problem with my Landcruiser 7 years ago and its been great since. Have a look HERE to see what you need to do to a HDJ78/79/100 series. My advice is to disable the EGr asap to prevent further carbon buildup.

Now we also have a VW - same problem but more complex electronics - the VW enthusiasts are keen on catch cans so that it ends up as dry carbon rather than oily carbon in the intake.