High egts & fuel consumption

[phibbzy]

Hi guys,

I have a 2003 D2a TD5 auto that for a while I've been trying to track down a high fuel consumption issue & now high EGT's to match.

Vehicle has a TRS remap, running standard tire height, roof rack with tent/awning, 40mm lift.

After cleaning the MAF a few months ago it seemed to perk up a bit but the best I can eek out of it is 14L/100. So I've just installed a pyro and straight away they're extremely high. I can hit 720 degrees easily on a straight and up to 950 on a 800 meter hill.
Cruise control @ 110 on an incline I will hit around 750 degrees.

Probe is located just prior to the turbo on the exhaust manifold.

I've cleaned the MAP which was clogged with grot, removed the EGR, changed the MAF over with another (questionable quality) unit and ran without it plugged in - all with the same results in exhaust temps.

On the MAF I'm getting 16.9k ohm on pins 1 - 2, 0.1M ohm on 2-3 and can't get a reading on 1 - 3 but the other one I have is the same with 16.8, NIL, NIL - either they're both good and my meter isn't good enough to properly read them or they're both stuffed - my money is on stuffed!

I'm starting to think I should get the injectors checked but is there anything I can check before going that route?

[sierrafery]

Hi, can be due to many things but you'll not be able to properly diagnose it without a tester, watch the temp gauge, is it going fast to the middle after you start driving?, not very relevant as well but if it takes long while it's not cold outside could be low readings from the ECT sensor which would increase consumption, the AAP sensor in the airbox is important as well... test tdive it with that unplugged too...which is not 100% relevant again... better find somebody with tester and get some live data readings that's the proper way of diagnosing this cos it's definitely an overfueling issue

[PhilipA]

HMM, my first thought was.

Vehicle has a TRS remap,
The question is , was it doing it before the remap?

Regards Philip A

[phibbzy]

HMM, my first thought was.

The question is , was it doing it before the remap?

Regards Philip A

Don't know!

I purchased the vehicle interstate with the remap being done as part of the pre purchase/minor remedy work before it was shipped over.

On the advise from JC I've wound up the actuator nut on the turbo. Took 9 complete turns to get it to the point where it overboosted on the highway test. 1/2 turn back and its happy.

The fuel is brimmed so I will see how it goes this weekend with ~500km worth of highway work on the cards.

The same gradient @ 110kmph on cruise control was at 620c instead of 750c.

I am still able to hit 800's flat chat up a short hill but this is a bit of an unfair test but I can work with this.

Perhaps the decat pipe and center box removal I'm building up will help it further.

[DiscoDB]

HMM, my first thought was.

The question is , was it doing it before the remap?

Regards Philip A

And what temp do you see when holding 110 when on a flat road?
Are you down on power or have plenty of get up and go?
How much black smoke you putting out when accelerating?
Are you sure the EGT reading is correct? I have seen Madman EMS give false high readings due to bad cable connections.

If you have access to a Nanocom, record and post the data from a run.

[phibbzy]

And what temp do you see when holding 110 when on a flat road?
Are you down on power or have plenty of get up and go?
How much black smoke you putting out when accelerating?
Are you sure the EGT reading is correct? I have seen Madman EMS give false high readings due to bad cable connections.

If you have access to a Nanocom, record and post the data from a run.

350-500 flat road at 110
A tad laggy to begin with - improved with increased boost. Overall power has increased a bit as well.

It disgorged black smoke prior and now I barely get a whiff.

2 different probes, 2 different gauges. Temps would be correct for idle etc - there does not seem to be any great disparity.

[Jason789]

Hello phibbzy,

Check if there is any oil at the ECU(oil in the loom). I had a similar problem that was intermittent, no remap though.

Cheers,

Jason

[phibbzy]

Hello phibbzy,

Check if there is any oil at the ECU(oil in the loom). I had a similar problem that was intermittent, no remap though.

Cheers,

Jason

Rocker harness is fresh, loom from engine to ECU is clear and so is the ECU.

[discorevy]

Don't know!

I purchased the vehicle interstate with the remap being done as part of the pre purchase/minor remedy work before it was shipped over.

On the advise from JC I've wound up the actuator nut on the turbo. Took 9 complete turns to get it to the point where it overboosted on the highway test. 1/2 turn back and its happy.

The fuel is brimmed so I will see how it goes this weekend with ~500km worth of highway work on the cards.

The same gradient @ 110kmph on cruise control was at 620c instead of 750c.

I am still able to hit 800's flat chat up a short hill but this is a bit of an unfair test but I can work with this.

Perhaps the decat pipe and center box removal I'm building up will help it further.

This sounds better and yep , it will help upon removal of cat and centre muffler , while you're at it , change the 42mm ID flexi for one of the same ID as the pipe, after this you may have to go back another 1/2 turn on the boost modulator,

[phibbzy]

This sounds better and yep , it will help upon removal of cat and centre muffler , while you're at it , change the 42mm ID flexi for one of the same ID as the pipe, after this you may have to go back another 1/2 turn on the boost modulator,

So the flexi joint is 42mmID? Yikes - thanks for that info!

[Tombie]

This sounds better and yep , it will help upon removal of cat and centre muffler , while you're at it , change the 42mm ID flexi for one of the same ID as the pipe, after this you may have to go back another 1/2 turn on the boost modulator,

Thats a hit and miss - some are 42mm and others full pipe diameter...

Quick torch down the flange soon answers the question :cool:

[discorevy]

Haven't seen a d2a with cat and full ID flexi , but there you go.

[Tombie]

Haven't seen a d2a with cat and full ID flexi , but there you go.

As I said, not doubting your experiences, the variability is crazy!

[sjane]

I can hit 720 degrees easily on a straight and up to 950 on a 800 meter hill.


950??? I thought something would go bang before then? Are you sure the measurement is correct? Surely the pistons would be melting?

Maybe stick the probe in a kettle and confirm ~100C?

The highest I have seen on my td5inside remap is 750C on steady climb, usually not going above 650C on 0 - 100 km/h flat out.

Fuel economy is pretty stable ~ 10L/100km with 245/75R16 MT and no other accessories.

Cheers,
Scott.

[phibbzy]

Thats a hit and miss - some are 42mm and others full pipe diameter...

Quick torch down the flange soon answers the question :cool:

Got a quote for $60 local for a 63.5 one... good thing I checked because its certainly a 2 1/2 on the one I'm going to use!

[phibbzy]

950??? I thought something would go bang before then? Are you sure the measurement is correct? Surely the pistons would be melting?

Maybe stick the probe in a kettle and confirm ~100C?

The highest I have seen on my td5inside remap is 750C on steady climb, usually not going above 650C on 0 - 100 km/h flat out.

Fuel economy is pretty stable ~ 10L/100km with 245/75R16 MT and no other accessories.

Cheers,
Scott.

950 is when I was ragging on it up a steep hill as a test. Thankfully I never did anything as nasty prior. Also I doubt from what I can find that the piston or head would be reaching that temperature, at least quickly.

I have been wondering what sort of damage I could have caused during the 8000km I've traveled with such a condition.

Now I know that even if the professionals do the tune & a pre purchase inspection its just no substitute for a pyrometer!!

[discorevy]

As I said, not doubting your experiences, the variability is crazy!

Yep, had seen plenty of early one's with full ID but haven't seen them all.........thankfully:)
phibbzy out of interest does the one you are going to use have a metal bellows type flexi with cat or no cat and steel braid flexi or even cat with steel braid?

[phibbzy]

Flexi type with no cat from an early d2 replacing bellows type with cat from this one.

[discorevy]

Cheers for that , I just saw that you had a d2a with cat and made the assumption you were going to use that pipe, ( yep , one should never assume), Have a look when you remove your existing one , pretty sure it'll be narrow ID
Cheers

[phibbzy]

Took the disco through 3 days of hills, twists turns and EGT hell with the result of rarely hitting the 700 degree mark while maintaining a desired comfortable speed. If i wanted to race car then yes, it peaks, but thats what the EGT is there for :)

500km on the odo with just over 1/4 a tank left - I was getting about 550 to a brimmed tank prior so considering 200ks of this was mountain climbs, low range, tracks, low tire pressures etc it is a vast improvement.

[Blknight.aus]

950 is when I was ragging on it up a steep hill as a test. Thankfully I never did anything as nasty prior. Also I doubt from what I can find that the piston or head would be reaching that temperature, at least quickly.

I have been wondering what sort of damage I could have caused during the 8000km I've traveled with such a condition.

Now I know that even if the professionals do the tune & a pre purchase inspection its just no substitute for a pyrometer!!

I really hope your EGT has a dodgy connection.

here's a link to a post I put into another thread on a similar topic.
http://www.aulro.com/afvb/1521229-post17.html