Blocking EGR

[groeschel Member Find all posts View Profile Close groeschel]

Hi xpro,
thats what I did:
I blocked the EGR port at the engine block completely.
I cut the connecting steel pipe to the EGR cooler and connected a 25mm airhose to the EGR cooler pipe.
The hose is now connected to the port for the resonator just behind the the airbox.
I tried for testing purpose to leave the the hose open with a small airfilter at the end but that didn't help either.
The best I got was a few hundred k without the engine light and that was on the free way when I expect the egr valve is closed anyway.
Is it possible that the ecu is expecting a increase of pressure in the intake when the egr is opening and the pressurised exhaust fumes are entering?
Cheers
Michael

Im sorry to hear its not working out for you. My cruiser is still going strong and a good few miles was put on.
Did you blank the egr at manifold and then created another inlet for fresh air?
Generaly the ecu will throw an engine light when the Airflow meter readings are too high when on cruise, and this happens when the egr is fully blocked. The error will be displayed as "insufficient Egr Flow".
If you can block the egr to stop the fumes entering the system, but instead create another port for fresh air, this will simulate the Egr operation and thus reduce the AirMass readings ( or airflow Hertz).

Regards,

[xpro Lurker Find all posts View Profile Close xpro]

Intresting read about EGR system , and about different tests conducted in diesel engines.

http://www.ias.ac.in/sadhana/Pdf2004Jun/Pe1131.pdf

[Matty80 Avid PP Poster! Find all posts View Profile Close Matty80]

Intresting read about EGR system , and about different tests conducted in diesel engines.

http://www.ias.ac.in/sadhana/Pdf2004Jun/Pe1131.pdf

Thats some good reading... Very informative!

Sounds like a particulate trap is as important to the EGR (in a 2-cylinder, non-turbo charged, LR, partially cooled system), as a catch can is to the blow-by...

[JGill Member Find all posts View Profile Close JGill]

Hi guys, some very interesting stuff in here.
I have learnt a lot about the benefits of blocking the EGR valve and I want to do this mod to my own car.
There seems to be a lot about the D4D in here. Mine is a 04 1KZ. I know a lot had been covered about this also but I am just wondering if someone can tell me the easiest and cheapest way to perform this mod on my car?
After reading this entire thread I am a little confused. Just a basic description of what to buy and how to fit it would be great.
Thanks for all the helpful info so far.
Cheers, Josh

[krypto Avid PP Poster! Find all posts View Profile Close krypto]

Intresting read about EGR system , and about different tests conducted in diesel engines.

http://www.ias.ac.in/sadhana/Pdf2004Jun/Pe1131.pdf

xpro, that seems to say that there is no loss in performance due to the EGR and that it helps lower exhaust gas and combustion temps. So from what I can tell the EGR only downsides are more smoke, and the big one is oil build-up on the intake, does that sound right?

Does anyone know if regular highway runs stop the oil film build-up in the intake..... Roo?

[uk_vette Junior Member Find all posts View Profile Close uk_vette]

2005 Prado
1KD-FTV
3.0 liter Auto.

I took the small bore rubber vacuum pipe off the actuating bellows.
I blocked the removed end of the rubber pipe, so no air in or out.
I left the bellows end open, as there is no point blanking it or whatever.

My findings,,,,,,,,
Didn't make a blind bit of difference.
No more power, no less power.
No more fuel, no less fuel.

I can't remember if the vacuum pipe is on or off now, I have an idea it's still off.

I should get around to putting it back on again.

Gra.

[xpro Lurker Find all posts View Profile Close xpro]

xpro, that seems to say that there is no loss in performance due to the EGR and that it helps lower exhaust gas and combustion temps. So from what I can tell the EGR only downsides are more smoke, and the big one is oil build-up on the intake, does that sound right?

Does anyone know if regular highway runs stop the oil film build-up in the intake..... Roo?

According to my research, EGR valve does increase EGT`s ( Exhaust temps and combustion temps) by re-routing some of 30% of the exhaust gas.
But the temperature changes in the cylinder when the egr is on are minimal, maybe by some +20 degress celsuis, which doesnt affect the engine at all, but it helps to lower the Nox percentage.
Most peoples theory is that an engine running without the EGR will suffer from high combustion temperatures, when in real life an engine thats running Wide Open Throttle or under constant load ( be it acceleration, towing, driving up hill,etc) the egr valve is closed, in order to maintain turbo boost pressure in the intake. This is when the EGTs are the highest, beacuse an engine need 100% oxygen to produce power.
( Also, think about it , what is the point of having an intercooler? if we want to do decrease the combustion temps?
Hotter the air, lower the density, worst performance! Cool air, higher density , better performance!)
Another reason to belive the egr is there at part time only, just to help reduce the nox, and nothing else.

Egr will engage in cruise conditions and part load driving, so at least some of the gas is recirculated and therefore the Nox levels are being at minimum.

The only problem in 3.0 d4d landcruisers is that EGR cannot be blanked as it is also used as a relief valve to dump the excess turbo pressure back into the exhaust.

Some Euro 3 versions will not throw a light when the egr is blanked, and euro 4 models will display MIL, due to insufficient egr flow, ( which is sensed by MAF readings. When the egr is blocked airflow meter readings are higer)so the only way is to bypass the egr as i did and let it use the fresh air instead of the exhaust gas.

Cheers

[xpro Lurker Find all posts View Profile Close xpro]

Does anyone know if regular highway runs stop the oil film build-up in the intake..... Roo?

It will certainly help but not significantly. Crankcase is always venting, and there will be an oil mist present at all times. The only difference with likes of motorway driving is the vacum in the intake will be higher so less chance of oil mist being deposited.

[DocK Member Find all posts View Profile Close DocK]

This is still a bit of a puzzle.

I noticed that the EGR cooler has 2 separate sections/chambers. One chamber has clearly been designed for cooling exhaust gases and the other chamber much smaller and not cooled. I assume that this means one is for exhaust gases coming to the throttle body and another for the over boost. But does anyone really know?

The problem here is I don't know how these 2 chambers combine and the front end or whether there is some sort of internal baffle that allows only one way flow. Where I am leading with this is as follows. If a stainless steel gasket was made for the throttle body end of the EGR blocking off only the exhaust chamber and not the over boost chamber would that work? Over boost would be covered, no alterations to the EGR valve operation - no error codes! Feedback appreciated on this please.

So has anyone cut up one of these EGR coolers to see how it is constructed inside???

Cheers
DocK

[Chip It Senior Member Find all posts View Profile Close Chip It]

Hi Skywalkerrun

I would like to discuss excess turbo boost on a diesel with you. I would prefer to do this over the phone rather thank on the forums.

Can you call me please 0412 304030

Cheers

[SWR Banned Find all posts View Profile Close SWR]

PM sent.

Cheers

[Chip It Senior Member Find all posts View Profile Close Chip It]

According to my research, EGR valve does increase EGT`s ( Exhaust temps and combustion temps) by re-routing some of 30% of the exhaust gas.
But the temperature changes in the cylinder when the egr is on are minimal, maybe by some +20 degress celsuis, which doesnt affect the engine at all, but it helps to lower the Nox percentage.
Most peoples theory is that an engine running without the EGR will suffer from high combustion temperatures, when in real life an engine thats running Wide Open Throttle or under constant load ( be it acceleration, towing, driving up hill,etc) the egr valve is closed, in order to maintain turbo boost pressure in the intake. This is when the EGTs are the highest, beacuse an engine need 100% oxygen to produce power.
( Also, think about it , what is the point of having an intercooler? if we want to do decrease the combustion temps?
Hotter the air, lower the density, worst performance! Cool air, higher density , better performance!)
Another reason to belive the egr is there at part time only, just to help reduce the nox, and nothing else.

Egr will engage in cruise conditions and part load driving, so at least some of the gas is recirculated and therefore the Nox levels are being at minimum.

The only problem in 3.0 d4d landcruisers is that EGR cannot be blanked as it is also used as a relief valve to dump the excess turbo pressure back into the exhaust.

Some Euro 3 versions will not throw a light when the egr is blanked, and euro 4 models will display MIL, due to insufficient egr flow, ( which is sensed by MAF readings. When the egr is blocked airflow meter readings are higer)so the only way is to bypass the egr as i did and let it use the fresh air instead of the exhaust gas.

Cheers

Xpro what you wrote is right. However, I do not agree with the theory that the EGR relieves turbo boost.

[Chip It Senior Member Find all posts View Profile Close Chip It]

Hi xpro,
thats what I did:
I blocked the EGR port at the engine block completely.
I cut the connecting steel pipe to the EGR cooler and connected a 25mm airhose to the EGR cooler pipe.
The hose is now connected to the port for the resonator just behind the the airbox.
I tried for testing purpose to leave the the hose open with a small airfilter at the end but that didn't help either.
The best I got was a few hundred k without the engine light and that was on the free way when I expect the egr valve is closed anyway.
Is it possible that the ecu is expecting a increase of pressure in the intake when the egr is opening and the pressurised exhaust fumes are entering?
Cheers
Michael

groeschel the EGR is open at cruise and thats why you get CEL ONLY at cruise/light throttle. Sitting at lights or under load the turbo supplies the MAP sensor/ECU with the pressure reading required.

At light throttle/cruise the throttle plate is closed forcing the engine to breathe exhaust gasses and starves the engine of oxygen rich fresh air. When pressure measured by the MAP sensor is low ... ie EGR is blanked and turbo pressure is not allowed to make it past the closed throttle plate the MAP sensor reports a low voltage ... ie PROBLEM. The manufacturers know that since the throttle solenoid is not reporting a fault the problem much be EGR flow.

As a side note, funny enough, the code that comes up under these circumstances is P0299 (turbo underboost)

[diver70 Lurker Find all posts View Profile Close diver70]

Would there be any benefit in fitting an oil catch can inline here? Aren't they designed to trap most of the airborne oil, so the remaining bit of air passing through the EGR system can be burnt without fouling everything else with oil? Just seems like a simple solution that would not create any error codes or performance losses. After all what is trying to be achieved is a cleaner intake tract, therefore more complete and efficient combustion ( more power), isn't it????

[Chip It Senior Member Find all posts View Profile Close Chip It]

cleaner intake yes, but also cooler AITs and less black smoke caused by low oxygen in the combustion chamber. Adds up to more efficiency