Manual Mapper Project for Toyota Diesel Engines

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

You blokes are to good for me but keep it up love reading all your comments,I'm being ENWITENED,
sorry couldn't resist it,
Enlightened, don't know if I should swop my 1kz for a d4d now if this might help the expensive injector problem I read about from time to time on PP.
CHEERS ALAN.

Upgrading from a 1kz is ok.
The 1kz is great! But as the owners know a bit slow, but not too bad & who's in a hurry?
The risks on the 1kz motor are cracked heads & glow plugs falling apart. One can be prevented.

The 1kd is a dream to drive in comparison!
There's nothing to worry about with a good 1kd if you follow my recommendations.
Injectors are virtually free if you play your cards right & you will save fuel.
So it's all good! Unless you trust bad advise from the old-school workshops.

Sounds like the manual mappers are working well & this may become highly recommended.

[Dabeanian Member Find all posts View Profile Close Dabeanian]

Hi ####,
Thanks for your reply,If I were to upgrade it would not be a new vehicle couldn't afford one so what's to look out for on a used KD engine wise,
I would always be thinking of injectors ,
would any damage have been done or does the damage just happen,
I suppose what I'm saying is could someone sell me a vehicle with bad injectors or does the problem just a cure if it's gonna happen.
Cheers Alan.

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Hi ####,
Thanks for your reply,If I were to upgrade it would not be a new vehicle couldn't afford one so what's to look out for on a used KD engine wise,
I would always be thinking of injectors ,
would any damage have been done or does the damage just happen,
I suppose what I'm saying is could someone sell me a vehicle with bad injectors or does the problem just a cure if it's gonna happen.
Cheers Alan.

Hi,

With respect to o.p, lets not discuss it here.
Please find a suitable thread & ask your questions again
I look forward to being able to help.

Cheers,

####.

[Dabeanian Member Find all posts View Profile Close Dabeanian]

Hi Anti,
Fair comment but always following Ozbush , and you by the way ,so new post.
Cheers Alan

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

Hi Gents,
I finally managed get proper connectors for EGR harness from UK.
Initially I got some from China but the quality was terrible and I couldn't use it (it will physically damaged the sensor) .
Second delivery was in reasonable quality which I chose to use it but not perfect.
The original one from Japan which manufactured by Shumitomo connectors are available but the cost was unbelievably high.
I chose middle quality connectors and it worked okay for me and other members so far.




At least now I have proper full plug and play system for our Manual Mapper for 1KD-FTV engines.
I have ended up 8 testers for Mapper all over Australia and one in UK. I do really appreciated for your help to develop the proper package.
There were some nasty surprises from two members with Hilux who had different type of connectors that they had which Toyota quietly changed to digital sensor without telling anyone.

I am doing further development for new Prado 150 and Hilux owners who has digital MAF sensors I think I should finished the programming and other upgrade mods for Prado 150 in the middle of next year and I may ask you guys to test for me again.
All is good so far, and Thank you.

Cheers
Ozbush

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

Hi Gents,
I have one more thing done which I would like to have your opinions.
Ever since I have fully blocked EGR system with full blanking plate and using mapper to prevent MIL, I have poured Nulon E30 long term engine treatment additive into my engine. It has been 7 months since I have added the E30.

My engines seems to be running like silk with far less noise with smoother acceleration.
I know you will be saying E30 is for petrol engine not for diesel.
But hey, what is so special about diesel engine?

I was always dissatisfied that I couldn't use E30 in diesel which I have put E30 in every petrol cars I owned and had incredible success.

I blocked the source of the soot with full blanking and changed engine oil and filter then ran 3,000 km to clean the engine thoroughly.

Then I changed oil and filter again and the engine oil was like new even if I have ran over 5,000 km since last oil change. Then I thought it was the time to add E30 when I had oil change third time. It was June 2015 when I added E30 into my engine.

So far my diesel is running like new and I am hoping the engine will last like all the other engines which I put E30.
Every engine I added E30, it was car body was perishing not the engine.
I am sound like Nulon salesman but fact is it works.

I have living evidence that I have 2004 Toyota Avalon which added E30 since new. The engine is still in absolutely brand new condition in every aspects after over 130,000 km. I have checked out with engine dynamo-meter and it still gives brand new engine output state.

I am not recommending that everyone should try E30 in diesel engine but what do you think.
I have no problem so far. My diesel engine runs like silk.

Cheers
Ozbush

PS: I have already posted above (similar) to other forums to see the consensus.

[Dabeanian Member Find all posts View Profile Close Dabeanian]

Hi OZBUSH,
Have you done anything for the Isuzu MUX
Alan

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

i have just done 2 long trips with the manual mapper & egr full blank

1st was from Adelaide to The Entrance in NSW & back (planned to collect a caravan but was rubbish)
did 1700km each tank for 173L sitting on 100 or 110km/h where possible 10.17L/100

2nd was Adelaide to Gympie & back
same deal 10.2L/100 on the way there 13.8L/100 on the way back towing a 18ft pop top sitting on 92km/h in 6th gear

both ways and towing i had the mapper on -3

next week we head to Perth for another round trip will try +3 or +5 for a tank to see the difference

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

Hi OZBUSH,
Have you done anything for the Isuzu MUX
Alan

Hi Alan,
Yes or no.
I have a friend of friend who has Isuzu Mux and wanted use our mapper and I gave him one without knowing the connections to MAF sensor.
He is auto-electrician and he figured all out himself and using our manual mapper very well apparently.
I can help you out very easily if you have a bit of patients to get our mapper on your car.
Ozbush

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

i have just done 2 long trips with the manual mapper & egr full blank

1st was from Adelaide to The Entrance in NSW & back (planned to collect a caravan but was rubbish)
did 1700km each tank for 173L sitting on 100 or 110km/h where possible 10.17L/100

2nd was Adelaide to Gympie & back
same deal 10.2L/100 on the way there 13.8L/100 on the way back towing a 18ft pop top sitting on 92km/h in 6th gear

both ways and towing i had the mapper on -3

next week we head to Perth for another round trip will try +3 or +5 for a tank to see the difference

Hi Razorback,
Great stuff, Thanks very much.
I haven't had many report on towing with our mapper.
I am all my ears for your long range towing report.
Merry Christmas and Happy new years to you and all.
Thanks for having fun.
Ozbush

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

Hi Gents,
This is a letter came from UK a gentleman who got our manual mapper 2 weeks ago.
With permission, I would like to share some interesting aspect of operation of Prado which is quite different to Australian spec.

"HI YOUNG
I finally had the the time to fit mapper and egr blanking plate fitted mapper yesterday which took five minutes, and plate today I will do a full clean of egr and manifold in summer, right now its winter here not much daylight hours to do the job. I noticed yesterday when I fitted the mapper the engine was quieter less clatter when cold in setting off and pulling away from giveways, Less noise and smoother engine at idle, When starting when engine from cold green light stays green for about a 40 seconds then alternate flash of orange than green, when engine is warm the colour is orange/green mixed together. Now blanking plate is in light stays full green with no orange hot or cold. I have mapper set on -3 car seems to pull with a bit more power than without blanking plate or could be my imagination. I will try it on +5 soon , what I am looking for is a smoother engine, cleaner engine oil (because of egr shut down),longer engine life and better fuel economy rather than more power although I would love more power but not at the expense of engine life and economy. I am very happy with your mapper. If you have any tips on the settings I would love to hear of them. I am sorry you had so much trouble posting mapper. I thank you very much for my mapper my car now runs much better.
Kind Regards
Tony
From: [email protected]
Subject: RE:"

What I noticed is the Prado in UK appears to have cold air EGR shutdown supported but not in Australia so far I come to finding.
I like to know if anyone knows about cold temp shutdown EGR here in Australia for Prado.

Cheers
Ozbush

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Once you get rid of the dirty hot unfiltered naturally you have to deal with more GO!!!
Cold air

These egr's run all the time, well except for times when the do shut off, not sure why, but some randomly shut 0%.

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

G'Day Ozbush,

I have started my EGR block and clean. I put the plate in for the block and cleaned the throttle body uo to the start of the inlet manifold as far as I could get in.
Now how to we do the EGR cooler hose block and direct vent of PCV?

The first photo do I just disconnect the hose from the EGR cooler and get some longer hose an run it straight to the thermostat housing?



Does this photo show the PVC part ?

[YMUS Find all posts View Profile Close YMUS]

So fellas tell me what the general opinion of the Manual Mapper. My 120 is running fine 220K and injectors good... 12lts/100K no load fully loaded with 18ft van 17-18l/100k. put 3" system on and was going to put in stienhauser chip and read about this mapper...
This guy really sounds like he knows what he is talking about... open for feedback fellas?

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

G'Day Ozbush,

I have started my EGR block and clean. I put the plate in for the block and cleaned the throttle body uo to the start of the inlet manifold as far as I could get in.
Now how to we do the EGR cooler hose block and direct vent of PCV?

The first photo do I just disconnect the hose from the EGR cooler and get some longer hose an run it straight to the thermostat housing?

[ATTACH=CONFIG]22034[/ATTACH]

Does this photo show the PVC part ?

[ATTACH=CONFIG]22035[/ATTACH]

Hi Winniliss,

I am so glad that you are doing those upgrades. Congratulations, you are the first one I have come across who are doing the best option to save the engine.
I have seen many other diesel communities doing what you and I do that includes many overseas people too.
I always said to do 3 things for modern diesel engines to save engine life and less repair costs with more power and fuel economy.

Those 3 things are...
1... Full EGR block with some suitable device to stop engine check light.
2... Stop EGR gas cooler developing the coolant leak and blowing the cylinder head.
You can just bypass the coolant hose from cooler after full EGR block.
3... Vent crankcase blow-by gas directly to air.
The blow-by gas entering back to inlet carries oil mist which mix with EGR exhaust gas soot and forming black mud cake to choke up and also causes premature engine wear. The blow-by gas also carries large amount of combustion product gas which completely harmful to healthy combustion by competing with oxygen which reduces power.

You could use Manual Mapper which will do the fuel trimming and EGR delete.
I have done many EGR blocks, EGR cooler blocks and crankcase direct vents for Mazda/Ford diesels.
In Toyota community no one seems to care about it despite I have seen quite a few blown EGR coolers. (I have seen piles of blown EGR coolers in my friends diesel workshop).

Furthermore, you can now use Nulon E30 long term engine treatment on your diesel due to clean engine oils.

For your installation of EGR cooler block and direct vent. I will come back to you with proper information. My other diesel Hilux which has 1KD-FTV engine has gone on holiday and hasn't returned yet.
I haven't done many on Toyota because no one seems to be interested on it.

Good on you Winnliss! I support you 100%.

Cheers
Ozbush