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Manual Mapper Project for Toyota Diesel Engines

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  • Manual Mapper Project for Toyota Diesel Engines

    Hi Gents,

    I would like to help Toyota community if I can with my little skill that I have.
    I was initially posting to other forum and never knew Pradopoint existed until few of members from here recommended to try out.
    I was pleasantly surprised the dedication of the members in this forum to help others. This forum is dedicated to Toyota so it should be.

    To briefly introduce myself,
    I am an electronics engineer who retired as a car computer design engineer who worked on engine control industry for all my life and seen many things. I retired around 2000-2005 and now doing other stuff. EGR and CRD system was starting to introduced everywhere at that time I saw few things about EGR systems when I was retiring.

    In 15 years since I retired, they have made so much advancement in motor control technology I had to catch up many things and learn quite a few things.
    I am not a mechanical engineer but have been trying to tame the mechanical things with electronics for a very long time so I do know few things and have seen many. I used to give no respect for diesel engines but one day it taught me a lesson I never forget (Terrifying Diesel runaway experience).

    I worked all over the world UK, US, Japan, Korea and Germany, of course in Australia.
    I learnt how to design and manufacture in extremely stringent quality control from working with Germans for many years in its military equipment.
    However, living in Australia almost 40 years taught me one more thing. That is being in flexible, the outback bush style.
    I am a desert lover and into many outback working and travel. But I still haven't done Simmo and Old telegraph track in Cape York.
    I can design and start manufacturing most of electronics out of nothing in overnight.

    The whole thing started and got me out of retirement was the damn EGR cooler which blew up on me.
    Since retirement, I was busy for other things and never bother to look at under the bonnet and not interested what's going on these days. Always given to my friend for service never wanted look under the bonnet.
    However, when I was faced with replacing new engine then it got my attention.
    I took a look at the current design and I was shocked that they implemented petrol EGR system straight into diesel engine. I was horrified. Petrol is clean burn, yes no problem but not on diesel. You cannot do that in diesel engine. I was actually surprised EGR emission diesel engine lasting that long which it shouldn't. Simply speaking, the diamond is carbon and the soot generated by low temperature combustion is also carbon, end of story. They are making a lot of money by making you buy car every few years. Now that is true pollution.

    The proper way to control diesel emission is to use HHO or Hydrogen injection which will make absolutely clean burn without any emission.
    Ferdinand of VW would have said same thing, I support what he did 100%. Good on you Fredi.

    I was going to do something about this evil design I was looking for a way to fix the EGR system. Before I realised I was surrounded by angry people who also wanted to do something about it.

    Few months of going day and night without drinking my beer (that was traumatic!) I finally made a device using micro controller chip to emulate EGR condition so car computer thinks all is ok.

    Click image for larger version

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    This photo is setting Mapper in economical setting 60/80/100km zone combined.
    Click image for larger version

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    I made 20 prototype sent out to forum members all over the Australia and tried out. It was a very good success and I finally have gone into production so I called Ozbush Electronics and it is now run by my daughter. Ozbush Electronics is sorely established by forum members and without them I wouldn't be doing what I am doing now.

    Now here is final crunch, the car I have currently driving and have worked on is Mazda BT-50.
    I used own many Toyotas and I still have Avalon.

    I used drive Prado and Hilux not anymore and I can not afford to buy another Hilux right now.
    Right now my Manual Mapper is only for Mzada BT-50 / Ford Ranger 2006-2011.

    I burrowed 2012 Hilux from my friend and worked out all the electronics.
    I was surprised that there was no difference in engine control system it is identical. I know why because car computer was developed outside of company, mostly they are using stock standard Bosch (Nippon Denso) computer anyway.

    So my current Manual Mapper for Mazda/Ford will fit perfectly.

    I would like to help and develop a device which will help 1KD-FTV engine. It will improve drive ability and engine longevity immensely. It will make truly unbreakable engine finally.

    I need to have a bit more information about 1KD-FTV engine in chronological order.
    I am only interested in EGR valve and EGR valve position sensor.
    Because there are difference in engine EGR design such as old one had no EGR position sensor but new engine has one. Am I right?

    Once I worked out then I can release 20 prototype for Prado members to try out.
    All I have to do is make some change in mapper software to adapt 1KD-FTV engine EGR sensing requirement.

    Reliability is my Forte, I am always tuned to be absolutely reliable in humanly possible way and I should get there once I start on this engine.
    I would expect to have some response from this forum.

    Cheers

    Ozbush.
    Last edited by Ozbush; 09-10-2015, 02:37 PM. Reason: Adding photo

  • #2
    Very interesting, I'll be watching this space
    Matt
    2008 120 GX D4D with a few extras
    Rig build here
    [url]http://www.pradopoint.com/showthread.php?33115-Mattfunk-s-120[/url]

    Comment


    • #3
      Originally posted by Ozbush View Post
      It will make truly unbreakable engine finally.
      We would all like to see that.
      Dave
      Views expressed are mine alone and are not intended to compromise the integrity of my employer nor offend those who may read such views.
      Bugger Bali, get out and see Australia before we sell it all to China.

      Comment


      • #4
        Ozbush.
        If you need a volunteer to trial the EGR unit i have a 2008 120 series. I have cleaned the soot from the EGR valve on several occasions and to finally stop it all together would be fantastic.

        Rusty.
        08 VX D4D, Lift, Safari Snorkle, Trailblazer Fridge, Custom Storeage System, BFG, ARB Safari Bar, Wife, Kids, Codan NGT HF Radio, Debt.
        06 100 Series Sahara, Bilteins, Kings, Beaudesert 3", Diff drop, Unichip Q4, Safari Intercooler, EGR delete, 20ft Bushtracker, Codan Envoy more coming.
        Sometimes i wake up Grumpy, most times i leave her sleep.

        Comment


        • #5
          Yep yep

          I support fredi too! Love it!

          Yes you are right, it has an egr position sensor.
          Last edited by Anth120playdo; 09-10-2015, 05:10 PM.

          Comment


          • #6
            Sounds promising, assuming this will be for the 150 as well?
            [B]Dave[/B] - 2010 Silver GXL Prado 150 TD Manual.

            Comment


            • #7
              Ozbush, I'm keen to help you out in any way possible. Looks like a great project you're undertaking. I'll send you a PM.
              [LEFT]Silver 150 Facelift
              TJM Bullbar, Lightforce Genisis Spots, Dual Battery System with bits from everyone, Powerful 4x4 slider/steps, Kaymar rear bar, "Genuine" Roof Racks, MSA Seatcovers, Dashmat, Tint, LED Interior Globes, Bridgestone D697s [/LEFT]

              Comment


              • #8
                Seems unanimous in support. Anything that solves the EGR issues can only be beneficial


                Sent from my iGizmo using Tapatalk
                2014 VX D4D. Dobinson 2 inch lift. TJM T3 Bullbar. rhino platform. TraxRax. Maxtrax. Dual batteries. GME TX3450.
                Setup to tow Crusader Muskateer caravan

                Comment


                • #9
                  Hi Gents,
                  Is anyone owns Toyota 1KD-FTV engine came with EGR position sensor in the engine?
                  It means the engine is less than 4 years old(?) and you can identify the EGR position sensor by looking at the rear of the engine cover at top on right side which has a little bulge and that is the EGR position sensor.
                  If you do have the engine with EGR position sensor then I can send out my current version of Manual Mapper to try out. I am sure it will work straight on.
                  Of course you must have EGR blanking plate installed (no hole, full block).
                  So let's not waste time just talking.
                  Any volunteers?
                  Ozbush

                  Comment


                  • #10
                    Rusty62 does your car has EGR position sensor?

                    Comment


                    • #11
                      Yes the 1kd-ftv has a egr position sensor
                      Last edited by Anth120playdo; 23-11-2015, 08:54 PM.

                      Comment


                      • #12
                        I have a 2011 Hilux with 165,000Km for work with a egr position sensor, and a 2014 Prado with 33,500Km with a egr position sensor. Would be happy to try one out on either, or one after the other. Let me know mate. Will order full blank off eBay if required.
                        Cheers,
                        Andy
                        [LEFT]Silver 150 Facelift
                        TJM Bullbar, Lightforce Genisis Spots, Dual Battery System with bits from everyone, Powerful 4x4 slider/steps, Kaymar rear bar, "Genuine" Roof Racks, MSA Seatcovers, Dashmat, Tint, LED Interior Globes, Bridgestone D697s [/LEFT]

                        Comment


                        • #13
                          The Aussie spec 120 series 1kz-te has a egr valve position sensor so I can't imagine the early 1kd-fte wouldn't?
                          Silver '04 KZJ120~Manual~GXL~Dobinson/Kings lift~Custom valved Ironmans~Detroit Locker~Endless Air~X9 Superwinch~Madman EMS1~TJM Dual Battery~Rhino Roof Tray~120W solar panel~Foxwing awning~Bushskinz UVP~Long Ranger water tank~Bushman fridge~Steinbauer P-Box~Beaudesert 2 3/4"~Airtec Snorkel~TJM Sliders~Prico Boost Gauge~BFG-KO2s~TPMS~GME TX3420~Front and Rear Cameras~Ultimate Camper hanging off the back!

                          Comment


                          • #14
                            Originally posted by Ozbush View Post
                            Rusty62 does your car has EGR position sensor?
                            Ozbush

                            Photo of EGR. Have made a full blank plate to install when you are ready.



                            Rusty
                            08 VX D4D, Lift, Safari Snorkle, Trailblazer Fridge, Custom Storeage System, BFG, ARB Safari Bar, Wife, Kids, Codan NGT HF Radio, Debt.
                            06 100 Series Sahara, Bilteins, Kings, Beaudesert 3", Diff drop, Unichip Q4, Safari Intercooler, EGR delete, 20ft Bushtracker, Codan Envoy more coming.
                            Sometimes i wake up Grumpy, most times i leave her sleep.

                            Comment


                            • #15
                              Ozbush
                              i have sent you a message on your phone
                              thanks
                              2008 Dune D4D manual GXL update - with lots of fruit !! + Roma Razorback Off Road Van

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