Manual Mapper Project for Toyota Diesel Engines

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

Just to clear the cobwebs, I thought the MAF was only used in a diesel engine
for EGR control, how does your device modulate the fuel flow using just the
MAF and the EGR?

Hi Leigh,
I am more interested in your alternator voltage booster.
If you don't mind I am asking.
What sort of concept behind of your product?
Ozbush

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

So your basically telling the ECU there is more "clean" airflowing through the system
so it can add more fuel?

Yes basically it is, but in reality there is a hell of lot more complexity behind.
You have to cater for every rpm and intake temp to compensated MAF value for. Otherwise car computer will just simply put MIL with error code.

[Rusty62 Advanced Member Find all posts View Profile Close Rusty62]

Well so far so good. Have done a few short runs 20 km or so and many stop starts.
Observations so far :
Boost comes on earlier than before.
More turbo whistle at idle.
Light throttle can see high boost pressure - max so far 15 psi @ 2500 rpm. It is not consistently high. Bit strange.
No alarms.

Yet to try adjusting the trim but will over the next week.

Doing a tow run in two weeks so will update then.
No fuel usage figures yet as my scan gauge dropped it memory when running Techstream.

Rusty.

[Rusty62 Advanced Member Find all posts View Profile Close Rusty62]

Another update. Now had the devise in for a week. No long runs but heaps of short stop start driving. No alarms.
Fuel usage seems the same as before as well but would need to do 5-600 km drive to really see if improved.
Still see some spikes in boost but not as high as when first installed.
The production unit will have all the plugs necessary to make it a plug and play unit.

More info to come.

Rusty.

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

i have had mine on for a week
we did a 490km trip with the camper on
using the info off the multifunction display for km to empty and the scan gauge for km/L
i filled up and it gave me a range off 1335km ( based on my current driving with the boat on )
driving i was running between 6 to 6.4 km/L
i generally get somewhere between 1200km to 1300km per tank towing
last tank was 1165km / 184L (not happy)

i set the manual mapper to -8 it didn't seem to loose any power
drove to the lower yorke peninsular ( reasonable wind) to collect 2 x kayaks to add to the top of the camper
scan gauge showed 6.8 to 7.4 km/L
range increased to 1380
after 200km and then adding the kayaks i turned it to +10, didn't notice much increase in power if any but scan gauge dropped to 5.5 to 5.9km/L
i stopped and turned it back to -10 after only 5km and scan gauge went back up to 6.8 to 7.6 km/L
we finished our day trip after another 120km camped the night
following day we drove home
scan gauge was mostly between 6.9 to 7.8 km/L
and range has increased to 1445km

i will say i was driving for economy sitting on 94 to 96 km/h ( but was using cruise )

at the moment i still have the 7mm hole in the plate ( waiting for the full blank to arrive)

mine is a 6sp and was driving in 6th towing

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

Hi Gents,

I am sorry for not posting here often. I had extremely busy matters related to this manual mapper and had no time to come and see here.
I had to go for adapting our manual mapper to a company who import trucks which originated from US military. They wanted to get rid of EGR system which is causing a big trouble due to outback condition here. They tried everything but couldn't because of smart computer. But with our mapper it was easy problem to solve.
This Euro 4.5 standard EGR emission control on diesel engine is a bad idea and mistake, it was so bad even the chairman of VW decided to cheat on this EGR system.
People who have this current system which disables the EGR shouldn't go for software update recall on their car computer system.
They should keep the car where it is. It is the best system they have for car's longevity and less cost to run the vehicle.
Thanks to former VW CEO.
I can imagine they are all going to cue up for recall and saying my car has software updated therefore the value of the car is now safe.
I feel like they are all cued up entering into slaughter house without knowing what's going on.

I will state this again for a guy who sent me a political righteousness mail to me. I am not against EGR system for petrol engines because petrol burns clean and there is no problem whatsoever, even if they lose some power and economy. But implementing petrol EGR system straight into diesel engine is a big F***up.

The diesel EGR system is new, only about 10 years old now. They tried petrol EGR system onto diesel and found worked ok for short period of time like 30-50,000 km and after that who cares tell them to buy new car it is good for our business.
Aha, are they now complaining about soot emission? Well simple, we will just put DPF and charge them more.
This Diesel Particulate Filter is even worse system. It is like Stone Age concept. Throw some fuel into muffler filter and burn the soot while driving.
What about extra fuel and carbon production?
Not to mention you need to do force burning by dealer time to time if you forget to drive long distance. You just pay for $900 extra for manual burn time to time. You need to replace entire DPF for $5000, when you can't reach the dealer in time to do force clean the DPF.
I recon the whole thing is producing more pollution itself. I will never buy a car with DPF diesel engine.
It is a nightmare. Just ask Subaru owner with DPF, they will tell you all about it.
I have a neighbour who had a car with DPF and he is so scared about DPF after he had to pay dealer $900 for forced burn cleans the DPF.
After that, he always goes out to country every weekend and drive at least more than 50km and hoping it did DPF self-burn.
The EGR system lowers combustion temp and causes un-burnt soot so it need DPF to burn it again with extra fuel (Can't you get it?), I think it is a joke.

There is a better way to control emission than using EGR and DPF. Some says diesel engine will be phased out in the future. In my opinion, it is totally opposite.
The diesel engine is our future. It is a high energy density fuel with safe non-flammable character and Biologically re-producible. All we have to do is just get emission control right.
I never go back to petrol engine, especially for 4wd.

I love diesel engine so much my wife thinks I am crazy.
Can't blame her because she caught me having sex with diesel engine. Few months ago, I put a folded blanket over the entire engine climbed up on top of engine and working behind of engine lying face down and she spotted me in prone position shouted me saying "Ahh that's what's happening these days you are so much in love with diesel engine now you are having sex with her. Of course she knows what’s going on but I recon she was jealous because I am spending so much time with it.

I will start posting new thread experimenting new emission control system soon using HHO when this Mapper thing is over.

Thanks for the due testing our manual mapper guys. Its good to hear that manual mapper is really working very well for fuel trimming.
I am surprised the results about the fuel trimming function which works so well. It's quite different to other brand of diesel engine.
The Toyota diesel engine is very responsive to fuel trim compare to other diesel engines.

I recon I can start releasing the mappers more for testing. But I need to make it completely plug and play. The main unit is completely plug and play but the EGR harness isn't. The connectors for EGR harness is coming from UK. In the mean time I might release the mapper with wire splice.

Please PM me or send me email to [email protected] if anyone wants to have a go.

Cheers

Ozbush

[Razorback81 Advanced Member Find all posts View Profile Close Razorback81]

just added the full blank plate
had a drive around the block and no code so far
will test it Thursday with the camper on again with a short trip to the river

[Rusty62 Advanced Member Find all posts View Profile Close Rusty62]

Full blank in, mapper on 0% and no codes to date.
Unfortunately family tragedy here so unable to do tow test.
Maybe in a couple of weeks after the funeral.

Rusty.

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Great post ozbush,

I can see you fully understand how bad the egr is.
There is only a minority that know how bad it really is & the extent of the damage.
If only we could plug in & update the people with our knowledge & experiences.


1kd-ftv egr mess.












Below With 7mm restrictor plate.
http://www.ebay.com.au/itm/EGR-Blank...-/191730029913



95+% fix.
If you like 100% & a few wires & maf adjustment, then watch this thread.

please don't do nothing & think all will be ok. Please also think about others, the family that buys your used vehicle.
Left standard damage is being done.

Also thanks to Rusty & Razorback for starting the r&d.

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

Hello Ozbush,
I wish to purchase one of your in-cabin units for my 2009 120 D4D. I will be doing the timing belt change / EGR clean very soon so I will install it then. I will also do the EGR coolant by-pass when you let us know how to do it at the same time.

Cheers Winston.

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

Hello Ozbush,
I wish to purchase one of your in-cabin units for my 2009 120 D4D. I will be doing the timing belt change / EGR clean very soon so I will install it then. I will also do the EGR coolant by-pass when you let us know how to do it at the same time.

Cheers Winston.

Hi Winston,

Good to hear from you.
You may do a little bit more when you are onto doing timing belt and EGR clean. Please don't forget the inlet manifold clean.
Many times I pulled my friend's inlet manifold and discover it has 70-80% blockage by soot plus PCV oil mist which forms a mud cake.
No wonder he had poor acceleration and bad fuel economy his engine was chocked to death.
You can also clean the visible areas of cylinder head and valves when you pulled inlet manifold. (You will be surprised how bad it is)
Don't forget to clean up and free the seized up swirl control valve or flap. I found it was always seized up.
After you clean up the inlet manifold and valves in the cylinder head area. Do the full EGR block by installing full blanking plate with our Manual Mapper.
When all is working then do the EGR cooler hose block to prevent leakage of the engine coolant and destroying engine.
It happened to me and others.
Then do direct PCV vent to air. Don't let piston blow-by gas and engine oil mist to enter the inlet manifold. I will post this one near future how to do it.
I measured on the engine dynamo meter around 12kw of extra power and thus more fuel economy. That is when you combined EGR full block and direct vent of PCV.
The EGR full block, EGR cooler hose block and direct vent of PCV are the common knowledge among 4wd enthusiasts in Europe and US. They all do it as standard setup.

Please visit my website to try out above ways,
http://ozbushelectronics.com.au/page2.php

Cheers
Ozbush

[Coolcol Moderated member Find all posts View Profile Close Coolcol]

Hi Ozbush, well you have got my attention! keen to see how your trials go.

Cheers
Colin

[floatingkiwi Lurker Find all posts View Profile Close floatingkiwi]

OzBush you asked a while back about 1KZ-TE systems.

As fas I know none of the 1KZ-TE's had a Maf sensor. All they have is MAP, IAT, Fuel temp, block temp.
Most of the later models also have a % EGR valve lift sensor, with the valve modulated by solenoid as you have already mentioned.

Blocking the off the EGR entirely normally throws no codes. My sensor is even stuck at 56 % permanently and throws no codes.... (I suspect the actual sensor is stuffed, I know the valve is not lifted from the seat.)

[Dabeanian Member Find all posts View Profile Close Dabeanian]

Hi Floatingkiwi,
I have an 06 120 with 1kz looked through workshop manual and can't see any mention of MAF sensor trying to get the information for Ozbush for my self but did read on another forum than PP , and a bloke said he had just cleaned his MAF sensor on a 1kz , he took a picture of the intercooler LHS with vacuum pipes, (he thought he got them mixed up and was looking for clarification ) looked to be the lower sensor below the one for turbo pressure but I don't know ?? ,the mapper could be what I'm looking for with the not so good economy of the 1kz and also for a bit more juice when towing the caravan up hills , once it gets going it's fine but the hills can make it the slug they talk about , been considering a chip to go with my 3 inch exhaust but the mapper could be a cheaper alternative but just reading comments at the moment to try to educate myself.
Cheers Alan.

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

OzBush you asked a while back about 1KZ-TE systems.

As fas I know none of the 1KZ-TE's had a Maf sensor. All they have is MAP, IAT, Fuel temp, block temp.
Most of the later models also have a % EGR valve lift sensor, with the valve modulated by solenoid as you have already mentioned.

Blocking the off the EGR entirely normally throws no codes. My sensor is even stuck at 56 % permanently and throws no codes.... (I suspect the actual sensor is stuffed, I know the valve is not lifted from the seat.)

Hi Floatingkiwi,

Thank you for your information. Yes I do agree with you. I couldn't find MAF sensor in that engine and most of them had no EGR system either.
Yes the MAP sensor is the one they only need to control the fuel injection.
Our Manual Mapper will work with the MAP sensor as well but it will become Turbo Boost Controller.

I will find out connectors for that engine to adapt Mapper to do Turbo boost control. It will control power and economy drastically.
Is anyone has this 1KZ-TE engine and living in NSW? I can take some photos for the connector and then I will come and fit it for you on the spot.

Cheers
Ozbush