ECU re-map and EGR Removal

[azzss Member Find all posts View Profile Close azzss]

Hey AZZSS
how much of an improvement have you found with the new tune?
lost or gained economy?
does it pull different in the higher gears?
do you tow much?

i have a 6 sp as well so interested in your opinion

i tried the pedal box and it was too quick on the throttle to get anything i tow of the line with ease ( plus couldn't let the wife drive it with it on )

mine is due for injectors & a EGR clean out then i might look into the tune

i tried the 3" exhaust ( have removed & refitted a few times to test the difference ) it's now off

i tried the full blank with manual mapper didnt gain or loos anything, but had codes come up a few times
currently have a plate with 7mm hole

am staying with the 65 series tyres to try not over gear it, as it doesn't tow well in 6th with the 70 series

thanks James

G'day James,
Mine was tuned by Agri tune locally in Warrnambool vic, and yes id recommend it. I'm on a trip with the family at the moment and have driven to cairns fully loaded up with 2 adults and 2 kids with all luggage (no towing) avg around 11/100kms. For the amount of grunt its got, and the way we didn't spare it much coming up (lots of 110km/h zones) and overtaking road trains I'm real happy with that. Yes i use it as a work vehicle so tow a lot and always up around the 2.5 tonne and pulled like a train, and pulled hard in 6th but i have a ultra gauge scan gauge through my iPhone so i tow keeping a eye on coolant temp, while it will pull in 6th up hill no problems, i will change back to 5th once coolant temp start to rise. I have only ran 65 series tyres on it (BFG's) for the reasons you pointed out. Im interested in what you said about the 3 inch exhaust, because i had a straight through muffler on mine before the tune and to be honest if felt doughy down low (loss of torque) so exhaust stays stock. I was considering doing it now with the tune done, but not sure if there is any gain in it.
Hope this helps mate, need to know more, fire away! :-)
Aaron

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

G'day James,
Mine was tuned by Agri tune locally in Warrnambool vic, and yes id recommend it. I'm on a trip with the family at the moment and have driven to cairns fully loaded up with 2 adults and 2 kids with all luggage (no towing) avg around 11/100kms. For the amount of grunt its got, and the way we didn't spare it much coming up (lots of 110km/h zones) and overtaking road trains I'm real happy with that. Yes i use it as a work vehicle so tow a lot and always up around the 2.5 tonne and pulled like a train, and pulled hard in 6th but i have a ultra gauge scan gauge through my iPhone so i tow keeping a eye on coolant temp, while it will pull in 6th up hill no problems, i will change back to 5th once coolant temp start to rise. I have only ran 65 series tyres on it (BFG's) for the reasons you pointed out. Im interested in what you said about the 3 inch exhaust, because i had a straight through muffler on mine before the tune and to be honest if felt doughy down low (loss of torque) so exhaust stays stock. I was considering doing it now with the tune done, but not sure if there is any gain in it.
Hope this helps mate, need to know more, fire away! :-)
Aaron

thanks Aaron

when you get back let me know what the fuel figure were like when towing that 2.5T
if your in Adelaide at any time we could fit my 3" for you to try if you like

we just upgraded our camper (1.1T) + our 18ft Coromal poptop (1.8T) to a Roma Razorback full off road van and it weighs 2.1T , it tows better that the 18ft tandem van and i dont notice the pull on the car like 18ft one and much less feed back through the towbar

but like you said using the scan gauge watching the temp i have seen it go from 84deg pretty much the std temp as the car on it's own
to 86 to 88deg with the van on
up to 95deg going up hills with the van on

have you had your injectors done ? did you have the egr cleaned out ? ( sorry if i have missed that somewhere)

thanks James

sorry for the little hijack !!

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

Not sure exactly how it all works Rob, but its been said that turning EGR off can effect excess boost dump from the turbo? (turbo dumps boost through EGR) so the theory goes. Just what I've read/heard. Mines tuned also, but EGR left on and plate installed with hole for that reason. Cheers mate

when i had the full blank in
i could see some issues on the boost gauge
if you got off the gas pedal and then straight back on i would get massive boost spike like 15psi even when your only just accelerating (not mashing the pedal !)
and with it running up to the 15psi it wasn't going like 15psi
and this is when i would see the code come up

with the 7mm hole it all went back to normal
now this it with the manual and auto may be different as the engine doesn't see reverse load like a manual does

even with all of this you still need to clean the little filter for the boost pressure module under the cover on the left hand side
when my car feels a little off i clean that out and off it will go again ( and i do the air flow meter as well at the same time)

James

[azzss Member Find all posts View Profile Close azzss]

thanks Aaron

when you get back let me know what the fuel figure were like when towing that 2.5T
if your in Adelaide at any time we could fit my 3" for you to try if you like

we just upgraded our camper (1.1T) + our 18ft Coromal poptop (1.8T) to a Roma Razorback full off road van and it weighs 2.1T , it tows better that the 18ft tandem van and i dont notice the pull on the car like 18ft one and much less feed back through the towbar

but like you said using the scan gauge watching the temp i have seen it go from 84deg pretty much the std temp as the car on it's own
to 86 to 88deg with the van on
up to 95deg going up hills with the van on

have you had your injectors done ? did you have the egr cleaned out ? ( sorry if i have missed that somewhere)

thanks James

sorry for the little hijack !!

Hey James,
I'll let you know when i get back to work mate, as i be towing again a fair bit. She cracked 2 pistons at 268k so had engine rebuild and new genuine injectors then. That is what happens when you let them go too far :-( got 385k on it now. EGR was cleaned then and put plate in not long after so i hoping is clean but might whip intercooler off at next service and have a look.
Cheers
Aaron

[azzss Member Find all posts View Profile Close azzss]

when i had the full blank in
i could see some issues on the boost gauge
if you got off the gas pedal and then straight back on i would get massive boost spike like 15psi even when your only just accelerating (not mashing the pedal !)
and with it running up to the 15psi it wasn't going like 15psi
and this is when i would see the code come up

with the 7mm hole it all went back to normal
now this it with the manual and auto may be different as the engine doesn't see reverse load like a manual does

even with all of this you still need to clean the little filter for the boost pressure module under the cover on the left hand side
when my car feels a little off i clean that out and off it will go again ( and i do the air flow meter as well at the same time)

James

You mean the little white map filter? i just replaced mine as it was chockers and cracked

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

You mean the little white map filter? i just replaced mine as it was chockers and cracked

yes that is it

[Rob L Junior Member Find all posts View Profile Close Rob L]

Not sure exactly how it all works Rob, but its been said that turning EGR off can effect excess boost dump from the turbo? (turbo dumps boost through EGR) so the theory goes. Just what I've read/heard. Mines tuned also, but EGR left on and plate installed with hole for that reason. Cheers mate

OK! I shall be looking into that then. Cheers AZZSS.

Also have found that the gearbox now seems to get a bit confused. It'll change up but then change straight back down (flairing??) and I'm assuming this is because of the extra torque. Are the gearboxes able to be reprogrammed and if so does anyone know a business in the Townsville region that could do this.

[lortap Lurker Find all posts View Profile Close lortap]

when i had the full blank in
i could see some issues on the boost gauge
if you got off the gas pedal and then straight back on i would get massive boost spike like 15psi even when your only just accelerating (not mashing the pedal !)
and with it running up to the 15psi it wasn't going like 15psi
and this is when i would see the code come up

with the 7mm hole it all went back to normal
now this it with the manual and auto may be different as the engine doesn't see reverse load like a manual does

even with all of this you still need to clean the little filter for the boost pressure module under the cover on the left hand side
when my car feels a little off i clean that out and off it will go again ( and i do the air flow meter as well at the same time)

James

Yep, ERG in 1kd allows dump of boost, so full block is not a great idea - where does excess pressure in turbo system go? 7mm hole seems to deal with it, but I still wonder whether it is restricting boost dump in some way. I have wondered if its possible to install a boost dump valve with a full block.

[Smithy - 120 D4D Senior Member Find all posts View Profile Close Smithy - 120 D4D]

Guys, I'm just weighing up the options for a power upgrade for my 2009 120 D4D, and only just starting to learn about ECU re-tuning - What are everyone's opinions on going this way rather than a Steinbauer or DP chip?

With a chip, if there are issues, the chip can be removed, whereas re-tuning would need another re-tune back to standard, which makes it more difficult to fix...

That said, is the ECU remapping a safer bet for engine reliability and longevity?

[Poppy Joe Member Find all posts View Profile Close Poppy Joe]

No Wastegate required.

Yep, ERG in 1kd allows dump of boost, so full block is not a great idea - where does excess pressure in turbo system go? 7mm hole seems to deal with it, but I still wonder whether it is restricting boost dump in some way. I have wondered if its possible to install a boost dump valve with a full block.

Variable-geometry turbocharger
From Wikipedia, the free encyclopedia
Variable-geometry turbochargers (VGTs), (also known as variable nozzle turbines/VNTs), are a family of turbochargers, usually designed to allow the effective aspect ratio (A:R) of the turbo to be altered as conditions change. This is done because optimum aspect ratio at low engine speeds is very different from that at high engine speeds. If the aspect ratio is too large, the turbo will fail to create boost at low speeds; if the aspect ratio is too small, the turbo will choke the engine at high speeds, leading to high exhaust manifold pressures, high pumping losses, and ultimately lower power output. By altering the geometry of the turbine housing to help the engine accelerates, the turbo's aspect ratio can be maintained at its optimum . Because of this, VGTs have a minimal amount of lag, have a low boost threshold, and are very efficient at higher engine speeds. VGTs do not require a wastegate.

[Dabeanian Member Find all posts View Profile Close Dabeanian]

Guys, I'm just weighing up the options for a power upgrade for my 2009 120 D4D, and only just starting to learn about ECU re-tuning - What are everyone's opinions on going this way rather than a Steinbauer or DP chip?

With a chip, if there are issues, the chip can be removed, whereas re-tuning would need another re-tune back to standard, which makes it more difficult to fix...

That said, is the ECU remapping a safer bet for engine reliability and longevity?

Hi smithy, I had my 09 120 KD re mapped about six months ago ( 230 ks ) the re map / tune , blocked of EGR increased boost to I think 18 psi ? but will check, bit more fuel something else will dig out email ,but it runs great plenty of umph now towing caravan of about 2300 ish all up and back of car with fridge and camping gear plenty of power for overtaking , just done 10,000 ks to Darwin and back to Perth, talking to Roger at Infinitech in Perth who did the job the re map is much safer for the car than a chip, I did ask the question,( right or wrong I don't know )
Must say it never missed a beat or has like I say I will dig email out for more info.
Cheers Alan.

PS , Just found email , boost to 18 psi and in earlier, increased torque limiters etc , adjustment to injector duration which allows more fuel. Power increase 150 NM & 40 HP .
really feels good anyway and probably 15 000 ks since it was done.
Alan.

[Benlux Find all posts View Profile Close Benlux]

Hi Poppy Joe so you can't see it being a problem if the EGR is 100% closer.

Thanks Ben

[Smithy - 120 D4D Senior Member Find all posts View Profile Close Smithy - 120 D4D]

Hi smithy, I had my 09 120 KD re mapped about six months ago ( 230 ks ) the re map / tune , blocked of EGR increased boost to I think 18 psi ? but will check, bit more fuel something else will dig out email ,but it runs great plenty of umph now towing caravan of about 2300 ish all up and back of car with fridge and camping gear plenty of power for overtaking , just done 10,000 ks to Darwin and back to Perth, talking to Roger at Infinitech in Perth who did the job the re map is much safer for the car than a chip, I did ask the question,( right or wrong I don't know )
Must say it never missed a beat or has like I say I will dig email out for more info.
Cheers Alan.

PS , Just found email , boost to 18 psi and in earlier, increased torque limiters etc , adjustment to injector duration which allows more fuel. Power increase 150 NM & 40 HP .
really feels good anyway and probably 15 000 ks since it was done.
Alan.

Cheers, Alan!

[Poppy Joe Member Find all posts View Profile Close Poppy Joe]

According to my local re-mapper No. As the name suggests its variable vanes control the boost and open to release boost.
When money is available I will be getting a re-map and egr shut down. Cost $1200, money well spent if you want to keep the car for a long time. I think with no exhaust going through the egr cooler the motor should also run a bit cooler so that too can be deleted and prevent a possible leek into the inlet manifold.
That's my thoughts.

[lortap Lurker Find all posts View Profile Close lortap]

According to my local re-mapper No. As the name suggests its variable vanes control the boost and open to release boost.
When money is available I will be getting a re-map and egr shut down. Cost $1200, money well spent if you want to keep the car for a long time. I think with no exhaust going through the egr cooler the motor should also run a bit cooler so that too can be deleted and prevent a possible leek into the inlet manifold.
That's my thoughts.

Yes but where does the variable vane turbo release the boost to? Has to go somewhere. My understanding is it goes back into the ERG? If ERG is blocked, this equals momentary boost spike - are you sure you know what effect this is having?