Manual Mapper Project for Toyota Diesel Engines

[Rusty62]

Fitted Ozbush mapper unit today. Full blank plate installed. So far so good with no alarms after 10 minutes. Will need to do a longer run to confirm no alarms.
Interestingly the Hilux and Prado have different coloured wires to the EGR sensor. Not sure if the EGR sensor is a different part number.

Hilux.




Prado.



Rusty.

[groeschel]

Hi Gents,

Two of our members got Manual Mapper and trying to get it working at the moment.

One thing made me surprise was the connector in the EGR harness was not right one.

Despite my friend who owns Hilux made quite sure that was the right connector but wasn't.
I will have to locate another connector from overseas very soon.

In the mean time, I would like to post the manual wiring for the EGR position sensor which I am posting it here.
http://ozbushelectronics.com.au/atta...FTV_Engine.pdf

I also have a very good quality wire splicer if you want to use it (easier than soldering).

Cheers

Ozbush

Hi Ozbush,
if you need a local truck to have play with and to check to connectors give me a buzz.
I am local to you and running a blanked EGR since years on my 2007 D4D (and ignore the MIL light ;-) 0
I send you a PM with contact details.
Cheers
Mike

[Ozbush]

Hi Gents,

Two of our members got Manual Mapper and trying to get it working at the moment.

One thing made me surprise was the connector in the EGR harness was not right one.

Despite my friend who owns Hilux made quite sure that was the right connector but wasn't.
I will have to locate another connector from overseas very soon.

In the mean time, I would like to post the manual wiring for the EGR position sensor which I am posting it here.
http://ozbushelectronics.com.au/atta...FTV_Engine.pdf

I also have a very good quality wire splicer if you want to use it (easier than soldering).

Cheers

Ozbush

[Ozbush]

Ok so the 1kd-ftv is basically the same from 2006 thru to current.
So I think once there is a working unit it should suit the range of engines.

If the egr is held in 0% position then no plank plate should be required.
So it won't matter if you have no blank or 7mm.
But I would still have 7mm, if there's any issues you know you have it 97% covered anyway. (mechanical reliability)

We will have to see what if any parameters change as a result of telling the vehicle it's coolant is under 10 degrees.
Fingers crossed.

Hi Anthony,
A month ago, I burrowed my friend's almost brand new Hilux with 1KD-FTV engine in it and still under new car warranty.
So he wouldn't allow me to install the blanking plate but I did play around other stuff.
I did install my mapper unit in the Hilux and I was hoping to see what ambient temp would shut down the EGR system like any other diesel EGR system in the world. I was playing around IAT (intake air temp) sensor in the MAF to see EGR shutdown but it never happened.
Toyota car computer would simply enable EGR all the way from -35c to +80c and never saw EGR shutdown.
All other diesel cars in the world do shutdown EGR system at below certain temp (around +5 to +10c) such as Mazda/Ford, Honda, Mitsubishi, Holden/Isuzu, Jeep, VW, Audi, and Benz but not Toyota.
So I was forced to abandon the IAT shutdown mode and concentrate in EGR emulation mode with blanking plate only for Toyota.
My friend wouldn't let me touch the car mechanically due to warranty. I couldn't try blanking plate.
So here I am looking for volunteers who don't mind playing around a bit.
Cheers mate.
Ozbush

[Anth120playdo]

Ok so the 1kd-ftv is basically the same from 2006 thru to current.
So I think once there is a working unit it should suit the range of engines.

If the egr is held in 0% position then no plank plate should be required.
So it won't matter if you have no blank or 7mm.
But I would still have 7mm, if there's any issues you know you have it 97% covered anyway. (mechanical reliability)

We will have to see what if any parameters change as a result of telling the vehicle it's coolant is under 10 degrees.
Fingers crossed.

[Ozbush]

Hi ozbush
I have 2010 150 prado in adelaide if you need a test vehicle
If not i will wait and purchase a production unit when all sorted
Can it work ok if egr is blanked with 7mm hole in plate or do we need a full blank
Cheers
Mike

Hi Mike,
I used drive a lot of Toyota cars but I am not really sure about all the new models.
In my opinion the best person to answer that is ############# (Anthony). I have great respect for him what he does here.
He lives with Toyota engines so ask him about it.
In near future, I will eventually get to that engine I promise.
Cheers.

PS: My way of dealing EGR is full block and emulate error code with electronics.

[Ozbush]

This is sounding better and better. Great work ozbush.
I am happy to help with any testing and trials but what sort of cost are you looking at once the product is tested and proven?

Hi,
I am a retired guy who wants to have some fun but very serious fun here for community.
I was in other forum before I discovered this tremendous forum. I already have on going product for Mazda/Ford units.
The most expensive part was automotive connector to make plug and play.
It will be definitely well below couple of hundred bucks.
Ozbush

[reddevil25]

Hi ozbush
I have 2010 150 prado in adelaide if you need a test vehicle
If not i will wait and purchase a production unit when all sorted
Can it work ok if egr is blanked with 7mm hole in plate or do we need a full blank
Cheers
Mike

[Anth120playdo]

I had a good chat with ozbush today, it's great to find another person who fully understands how bad these egr systems are.

So lets get one plugged in & see how it goes. I'm sure you will make it work.


Next will be coolant by-pass to prevent the catastrophic event of an egr cooler leaking internally.

[MRW82]

This is sounding better and better. Great work ozbush.
I am happy to help with any testing and trials but what sort of cost are you looking at once the product is tested and proven?

[Ozbush]

Ozbush

You may just be the messiah we have all been waiting for...

Does the Manual Mapper live in the cabin or is it installed in the engine bay?

If you need more volunteers, give me a yell via PM.

Hi Rorza,
It is a natural development. The above suggestions are already rampant in US and Europe. Just about every 4wd enthusiasts in US knows about those facts.
I think we have some catching up to do. We do certainly need more of these stuff because of our extreme condition in outback.
I think Toyota community need to catch up a lot more because the numbers you guys have.
And yet I found Toyota community has a lot of resourceful people especially here in this forum.

All you need is lower your pride a little bit and work together then we can catch up the rest of the world.
I am here to help that is my joy when someone got it going.

My mapper is one of the natural development by requirement.
You've got to endure the giant corporations onslaught, which is throwing the candy to fool us with all the gadget which isn't really worth anything, whilst they making you to buy more and more stuff every few years with your hard earn money. I think we led in dark which in turn truly making more pollution.

I'd better shut up here before I get a visit from MIB.

BTW, My mapper has two version, in cabin and under the bonnet version.

I will post here the picture of in cabin version.


I will try to post better pic just got no time.

Cheers

[rorza]

Ozbush

You may just be the messiah we have all been waiting for...

Does the Manual Mapper live in the cabin or is it installed in the engine bay?

If you need more volunteers, give me a yell via PM.

[Ozbush]

Hi Gents,
I am sending out two manual mapper to two members to work out initial get up and go.
Once I figured out it works ok then I will send out more for test.

I have some suggestion to make your engine work much better and last a lot longer and trouble free while you are driving.
I would like to see truly unbreakable engine and to be that I have some suggestion which worked out pretty well with other brand diesel engines.

1... Get rid of uncertainty of injector seal problems. Get new graphite coated copper seals for better sealing of injectors. I found cleaning and polishing the contact surface of the injector well in the head is the key to longer lasting seal.

2... Get rid of EGR system completely which doesn't even work after 50,000 km due to blow-by. You don't know how much EGR is damaging to your engine. Having 7 mm hole blocking would suffice, but I rather do the full block and address error code or CEL electronically. After the full EGR blanking then block the EGR cooler hose to stop developing the leak and damaging the cylinder head or whole engine.
According to my friend mechanic survey since 2005, He has seen the EGR cooler failure from all company's and models including many German brands. They are ticking time bombs to blow up one day and nobody knows when.
In my case, brand new EGR cooler blew up only after 2000 km and crack the cylinder head.

3... Vent crankcase gas blow-by directly to air. Having Provent 200 is the best choice if you insist, due to preferring inlet manifold lubrication such as to swirl control valve but the replacement filter is expensive.
I found more power around 12 kw in engine dynamo-meter when I had full EGR block and venting crankcase gas directly to air. You know why it is.
You can have up to or over 10% of blow-by gas per cylinder can enter the inlet air manifold. They need fresh oxygen to have best performance not the mixed blow-by gas which is totally harmful to combustion.

4... Free yourself from globally fixed setting of your car computer for your own choice. It was a very difficult thing to do in old days but now everything is electronics control why not have a dial in your cabin or engine bay to change your engine characteristic by means of altering the fuel delivery more or less.
My fuel trim device was the idea in the mapper you can alter fuel delivery down to -15% or all the way up to +15%.
You can set mapper to -10% when you have empty car for maximum economy or set to +8% when you are carrying heavy load or racing.
The mapper can do all that by just manually dialing, hence I called it Manual Mapper. Many people achieved incredible economy up to 5.8L/100km in 3.0 liter diesel engine.
People found every car has its own character even in same model same engine. Also everyone found their own preferred spot in the dial setting.

Above 4 suggestions has been working in other brand diesel engine for a very long time. Why not do the same in Toyota Engine?

Don't trust my words, try it yourself. You will find above mods are definitely worth a try.

Ozbush

[azzss]

I'll have a go at this too if you need anymore!
Cheers

[Razorback81]

Ozbush
i have sent you a message on your phone
thanks