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View Full Version : 2.7 TDV6 EGRs and ECU Mapping



101RRS
19th July 2012, 05:46 PM
An update on a couple of different threads running.

My EGRs started playing up just before Christmas but may have just been connector issues.

After a trip to Melbourne last month the Engine Management Light (EML) was on and the codes showing failure of both EGRs. I ordered replacements from the UK. Now my car is an 07MY and at the time the consensus was that these (and later models) could not be blanked without the EML being on (see Ean Austral's thread on these). BAS in the UK has been working on this and while my EGRs were enroute from the UK he released an ECU remap that supposedly solved the problem.

As I had been thinking about getting a performance map for my ECU I decided to get a job lot of performance map, egr map and EGR Blanks for a extra special price - because I am special :).

The BAS system requires you to download your engine map to an interface device and then email it to BAS who then remap it to your requirements and return it to you for upload to the car ECU. This highlighted the first issue with the EGR remap - the early 07MY engines have a different map to later 07/08/09MY engines and basically the new EGR remap does not work - the EML will still stay on for blanked engines if the EGRs have failed - however I plugged my new EGRs into my wiring loom with and without the new EGR map and no codes and no EML - so as long as the EGRs still work early 07MYs can be blanked with no further mods. If the egrs are shagged the maybe a soon to be developed electronic module that mimics the EGR function electrically is the way to go.

Today I got my performance map for the ECU. BAS was concerned about our poor quality of diesel fuel and exhaust smoke and has given me a moderate across the board map to test. Uploaded it today and initial thoughts were only a mild increase so I did some 0-100kph times.

With the original map in auto I managed an average of 14.02 secs for the 0-100kph time. With the map installed this dropped to 12.4 secs - so quite a massive improvement. Sport mod was no quicker than normal auto - 0-100kph 12.48 secs (one run only).

As I have no smoke on acceleration etc and the engine is able to cope with the mild map I will get a higher performance MAP next week.

Not sure how BlueFin goes - one acquaintance had issues but the BAS map is a winner for me.

Also on the EGR front, pre 07MY can be blanked, late 07MY and later MYs can be blanked with the BAS EGR Remap but early 07MY engines cannot be blanked if the EGRs are not serviceable - the way around is to leave the old ones connected to the exhaust but connect new ones to the electrical connectors.

BAS are still working on the issues and I am sure new releases will be made in the future.

Garry

Ean Austral
19th July 2012, 05:55 PM
Gday Garry,

Glad to hear the re-map has been a success, will think about it in the future, but not being very computer savvy I may struggle.

Will be keen to see how the EGR blank proceeds.

Cheers Ean

Fatso
20th July 2012, 09:42 AM
Gday garry , thanks for the heads up on this topic , did you actualy fit the blanking plates and remove the butterfly etc when sorting this out or did you just plug the new egr in . My RRS is Jan 2007 build and egrs are ok or at least no alarms etc , so was thinking of getting a blanking kit from Bas . As some posts on the RRS in england site for early 2007 RRS had done the blanks and no alarms etc ,so thought it might be worth a shot .

101RRS
20th July 2012, 11:34 AM
Gday garry , thanks for the heads up on this topic , did you actualy fit the blanking plates and remove the butterfly etc when sorting this out or did you just plug the new egr in . My RRS is Jan 2007 build and egrs are ok or at least no alarms etc , so was thinking of getting a blanking kit from Bas . As some posts on the RRS in england site for early 2007 RRS had done the blanks and no alarms etc ,so thought it might be worth a shot .

I fitted the full BAS kit so have removed the pipes and butterfly. If you car is a 06MY (but 07 build date) you should have no issues blanking but if your car is like mine an early 07MY (May 2007 build) then you may have issues if there are issues with the EGRs.

Really, blanking the EGRs on the outlet side might have a positive impact on the health of the induction system but does little for the health of the EGRs as they are still exposed the the exhaust gases - the EGRs fail not because of carbon build up but the actuator/electrics fail because of the hostile environment. So the right way would be to blank them between the exhaust and EGR but it is a mongrel of a job to remove and replace the EGRs - hence I have my new ones mounted remotely to provide the correct electrical signals to the ECU.

Blanking your EGRs as long as they work should be successful but your EGRs may still be prone to failure in the future.

Garry

Ean Austral
21st July 2012, 11:00 AM
I spoke with a guy from the D3uk site and he only loosened the EGR's and put a slot in the blank he made so as the blank could slide down over the bolts and then he just re-tightened the EGR.

I believe that this is the correct way to blank as Garry has said, but mine still have working EGR's when I tried, so I think something that sends a signal to the ECU is also needed to fool the system into believing all is still connected.

Cheers Ean

101RRS
21st July 2012, 11:17 AM
so I think something that sends a signal to the ECU is also needed to fool the system into believing all is still connected.

Cheers Ean

Your 08MY engine has smarter ECU coding than the My06 and early My07 so according the BAS just blanking will not work (but your experince would indicate it might be possible) so BAS developed the EGR map for your engine which works with blanks and serviceable EGRs. Is relative cheap if you already have the BAS interface device or top level ECU code readers/programming equipment but is more expensive if you also need to buy the BAS interface device.

However if EGRs are not serviceable I am not sure it works so BAS needs to consider developing a small electronic plug in device to replace the electrics of the EGR and trick the ECU that it has ECUs connected.

Garry

Fatso
23rd July 2012, 08:43 AM
Any faults from your mod yet , do you still have the new egr,s connected and tucked up out of the way ????.

101RRS
23rd July 2012, 11:11 AM
Any faults from your mod yet , do you still have the new egr,s connected and tucked up out of the way ????.

No faults - no issues - I have wrapped the egrs up in bubble wrap and gaffa tape and they currently live on either side of the engine cover plugged into the wiring loom - with the bonnet closed they do not move.

https://www.aulro.com/afvb/

It seems the correct connectors are not available so I will have to make some up myself that may take a little time. I will then mount the egrs up behind the battery box on the drivers side (top left of the pic) and run a connecting cable to each from the connectors on each side of the engine.

Garry

Fatso
23rd July 2012, 07:56 PM
Good one ,thanks for update hope this is your problem solved , will probably go down this road myself. Wondering if you can access the plugs from a wrecker . ?

101RRS
30th July 2012, 10:08 AM
Final Map is now installed - my 0-100kph time is now just 12secs so about 2.1 secs faster than the unmapped engine. With the new map the gerabox has not yet responded to the increased torque and is still changing up a little early so hopefully with use will increase. The change up at 60kph with foot flat to the floor is a little early but it booms on after that - at 100kph and above (overtaking speed) the engine is really pulling and will be great when towing.

Also with this latest version Sport mode is back - coming in at around 11.8 secs. These times are with foot off the accelerator and on the brake and times start when the brake foot moves to the accelerator so would be quicker with left foot on the brake - engine revs up to torque converter stall speed and then release the brake but it is not worth the risk to the drivetrain.

As far as the EGRs are concerned - still no issues and thanks to the Disco 3 UK forum I have found a place that can supply connectors so will make up some cables to properly mount the EGRs remotely.

I have now started putting in 2 stroke oil in the fuel but not noticed any changes to the running of the engine so I guess the benefits will be long term with extra lubrication to the injection pump etc.

Cheers

Garry

BigJon
17th October 2012, 01:46 PM
Can you tell me where you got the blank kits, remap, etc from (website link, etc)?

My dad has an 06 2.7 and it logs EGR faults. I would like to fix the EGR problem once and for all and a remap wouldn't hurt either.