Manual Mapper Project for Toyota Diesel Engines

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

Installing EGR blanking Plate and Venting Crankcase gas directly to air

Hi Gents,
Quite a few Prado point members were asking me about how to install EGR blanking plate in Toyota 1KD-FTV engine.
I have promised couple of months ago that I will post about it.

I have full write up about how to do it with full illustration.

I have posted in my website. Please visit my website and download it if you wish.

Download link is http://ozbushelectronics.com.au/page2.php

I have written for installing EGR blanking plate and Venting Crank Case Gas directly to air.

Please ask me if you have any further questions about the articles.

Cheers
Ozbush

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

Please ask me if you have any further questions about the articles.

Cheers
Ozbush

In your how to write up, you say:

Caution!
The two bolts in the flange are very easily damaged by over tightening.
Be very careful not to over tighten the bolts. These bolts are very soft metal and the thread will be stripped very easily.

In that case, maybe it would be a good idea to specify torque required for those nuts. Under tightening due to concerns about stripping the threads may result in leaks. Also note that you call the nuts 'bolts'

[Tony120 Lurker Find all posts View Profile Close Tony120]

Hi ozbush,

My manual mapper has arrived and I installed it yesterday, all seems to be working well.#

Quick question for you... I have an obd2 wifi unit sending engine data to my phone, does the mapper affect the instantaneous and average fuel economy it shows?

so far showing 8.4L/100km average over approx 150km which is a massive improvement#(set to +5)

I'll post some updates as I get some more results

Cheers, Tony

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

Tony120, Hi mate, I have just ordered my in cabin manual mapper and it is on its way. I have all the bits I need to do the the blank off and the coolant removal from the Cooler. 8.4L/100 sounds great. What were your previous figures??? I have been getting 9s. I am very interested in seeing what my oil is like after the next oil/filter change. #### says the oil is so much cleaner for so much longer. Take care and cheers Bill.

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

Ozbush, Hi Young, Hope one day to have that Swan Larger with you. Thanks and cheers Bill.

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

Ozbush, Hi Young, Hope one day to have that Swan Larger with you. Thanks and cheers Bill.

[Tony120 Lurker Find all posts View Profile Close Tony120]

Tony120, Hi mate, I have just ordered my in cabin manual mapper and it is on its way. I have all the bits I need to do the the blank off and the coolant removal from the Cooler. 8.4L/100 sounds great. What were your previous figures??? I have been getting 9s. I am very interested in seeing what my oil is like after the next oil/filter change. #### says the oil is so much cleaner for so much longer. Take care and cheers Bill.

Hey chardo, realised today I had it set on -3ish, I've now set on 0 from a full tank so will get a real economy figure as well as the "torque" obd2 app figure (so far 8.8L/100km after 200km of windy hilly 110km/h hwy driving) I was getting 12L/100km previously - fairly loaded with winch, steel bar, roofrack, drawers, heavy foot, etc. also got a K&n filter since last check though.

Still have to get to the cooler bypass and oil catch can

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

Tony120, Hi Tony, I have fitted a Scangauge 11approx 5 weeks ago and still learning to drive it. I live approx 112km from Darwin so I am still getting lower L/100 figures as I get further into the kms. I have found that I get slightly better figures sitting on 110kmh rather than 100kph. we have a 130kph limit up in the NT but I am a grey nomad so I use the lower limit lately. I fitted a Provent 200 catch can approx a year + ago. I will be checking on the EGR valve when I fit the blanking plate to see what has happened in there. I bought the heater hose today to do the coolant bypass. Im really looking forward to seeing the difference when all in. The main reason I got into all this was I had lost the Cooler holding bolt and cracked the Cooler around the pipe join (I think). I can see a lot of black soot on everything under the pipe. It must be a minute crack as I have taken photos with my mob phone and can't see anything, but that has to be where it is coming from. I have sealed around the pipe join with High Temp silicon and it seems to have stopped sooting, so fingers crossed. The blanking plate and Youngs Manual Mapper will delete the Cooler so I have saved $770 for new Cooler in Darwin. Must go and get some shut eye. Cheers Bill.

[Mozz Member Find all posts View Profile Close Mozz]

Tony120, Hi Tony, I have fitted a Scangauge 11approx 5 weeks ago and still learning to drive it. I live approx 112km from Darwin so I am still getting lower L/100 figures as I get further into the kms. I have found that I get slightly better figures sitting on 110kmh rather than 100kph. we have a 130kph limit up in the NT but I am a grey nomad so I use the lower limit lately. I fitted a Provent 200 catch can approx a year + ago. I will be checking on the EGR valve when I fit the blanking plate to see what has happened in there. I bought the heater hose today to do the coolant bypass. Im really looking forward to seeing the difference when all in. The main reason I got into all this was I had lost the Cooler holding bolt and cracked the Cooler around the pipe join (I think). I can see a lot of black soot on everything under the pipe. It must be a minute crack as I have taken photos with my mob phone and can't see anything, but that has to be where it is coming from. I have sealed around the pipe join with High Temp silicon and it seems to have stopped sooting, so fingers crossed. The blanking plate and Youngs Manual Mapper will delete the Cooler so I have saved $770 for new Cooler in Darwin. Must go and get some shut eye. Cheers Bill.

Why not just block the EGR cooler at both ends and leave it at that.

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

Why not just block the EGR cooler at both ends and leave it at that.

Chardo,
You are a very lucky person that it cracked such way exhaust gas is leaking, imagine if you had coolant leak instead of exhaust gas, you would had lost cylinder head!
It should be okay now if you blocked it at very beginning side of EGR pipe flange which is directly off the exhaust port.
No exhaust gas will ever enter the system. However you still need to seal them up to prevent inlet air leakage which can effect power and mileage.

I am going for CapeYork this year and I will definitely come and see you for Swan Lager. I have been in your town many years ago I remember the Inn and memorial.

Ozbush

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

Hi ozbush,

My manual mapper has arrived and I installed it yesterday, all seems to be working well.#

Quick question for you... I have an obd2 wifi unit sending engine data to my phone, does the mapper affect the instantaneous and average fuel economy it shows?

so far showing 8.4L/100km average over approx 150km which is a massive improvement#(set to +5)

I'll post some updates as I get some more results

Cheers, Tony

Hi Tony,
Yes it does effect fuel economy more or less depending on how you set the mapper.
It can give you the fuel usage from 10L to 8L/100km quite easily but then it can be only for your car.
I have a gentleman claiming he gets 6.3L/100km from 10. (Maybe just for gentle downhill running).

Your car will be gutless if you set it -10% or lower. But depending on your car load or driving habit.

Tried to set the scantool program for long term fuel usage. I use Torque Pro in my mob phone it gives me very accurate reading of fuel usage between tank to tank. I do save a lot of fuel cost when I set on -7% but only for empty car.
Let me know how you went.
Cheers
Ozbush.

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

Hi Gents,

One of Prado members told me that one file is missing in my website.
That was How to bypass crank case re-circulation on 1KD-FTV.

Thanks for that I have restored it since your email.

Thanks PhotoPrado describing the bolts instead of nuts also have been corrected:grin:.

The torque setting on the flange nuts are 10nm according to my friend who was reading out on Toyota workshop manual but I wouldn't go on that. I would probably go for 8nm. Just go for feel is better on that situation. You turn it until it stops then go for half turn more or keep turning until you feel the threads are just starting to move up.
Even if a bit of gas leak so what you just tighten up until stops. Oh I need some help here from expert on thread.

Cheers
Ozbush

[Tony120 Lurker Find all posts View Profile Close Tony120]

I use Torque Pro in my mob phone it gives me very accurate reading of fuel usage between tank to tank.

This is the answer I was looking for, i'm also using Torque Pro and I was wondering if the fuel usage figures were accurate when using the mapper

Cheers

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

This is the answer I was looking for, i'm also using Torque Pro and I was wondering if the fuel usage figures were accurate when using the mapper

Cheers

Yes Tony,
I got Torque Pro apps and actually checked out for real fuel usage between tank to tank.
It was almost same and was out only by 1.8-2.2 litres AVG.
So the program is deadly accurate for fuel consumption measurement for long term L/100km setting.
I get around 6.8L/100km in motorway running from Sydney to Newcastle 150km of distance at 100kph in my manual geared Hilux with 1KDFTV engine.
My mapper setting was usually -5%.
I set mapper to +8% for caravan towing and I still get around 8-9L/100km.
Above figures are only for my car which has all the mods.
I have 3 inch exhaust, In cabin Mapper with full EGR block, crank case gas vent directly to air, EGR cooler block and about 250kg of camping gear load constantly at the back of ute.
The 3 inch exhaust does give me more instant power when I needed but it didn't contribute to fuel economy much.
Fuel consumption figure was same before and after the new pipe.
However, that $100 knock off version of snorkel gave me a lot of difference in power and economy especially hearty 2500-3000 RPM running.
I got a lot of benefit having snorkel. It somehow changed characteristic of the engine. I think it is about resonance length of the inlet pipe for charged air depending on RPM.

Cheers
Ozbush

[brogers Advanced Member Find all posts View Profile Close brogers]

Hi Gents,

One of Prado members told me that one file is missing in my website.
That was How to bypass crank case re-circulation on 1KD-FTV.

Thanks for that I have restored it since your email.

Thanks PhotoPrado describing the bolts instead of nuts also have been corrected.

The torque setting on the flange nuts are 10nm according to my friend who was reading out on Toyota workshop manual but I wouldn't go on that. I would probably go for 8nm. Just go for feel is better on that situation. You turn it until it stops then go for half turn more or keep turning until you feel the threads are just starting to move up.
Even if a bit of gas leak so what you just tighten up until stops. Oh I need some help here from expert on thread.

Cheers
Ozbush

Hey dear Ozbush, perhaps it is best to stick to designing and describing the electronics that you know so well, and maybe leave the "mechanical" or "diesel fitting" aspects to those particular experts

Just a friendly and jovial suggestion