Thread: DIIA EGTs and other things

I think the first thing you should do is buy an Allisport or Serck larger intercooler.

I have a BAS retune,21lB boost , delete EGR , and delete cat , Serck intercooler, and EGT gauge in manifold near turbo. I have also replaced the grille with stainless mesh with 70% void.

I have a similar problem although I don't tow 2 tonnes. When I tow my camper trailer I really have to avoid cruise control or even moderate hills will see the ECU run flat out and EGTs go to 750.

Without towing I can now leave cruise on for nearly the entire Hume Highway.

I don't now think that delete EGR and Cat do that much . The best bang for buck is the intercooler. I didn't stage the mods so I don't really know which is most effective with the exception of the intercooler which made a big difference.
Delete EGR is mainly to keep crap out of the inlet manifold , although an oil separator will do most of that anyway.

I cannot comment on the aggression of the TRS retune but I don't think mine is particularly aggressive as I don't get any smoke at all.
So IMHO even after you get a bigger intercooler you will still have to watch EGTs.
One way to reduce EGts is to change down early to increase revs.
Regards Philip A

Following this! as I have just started towing my van with my D2a also, weighing 1900kgs and towing home down the Bruce hwy from Coolum locked 3rd at 3000 temps were stable around 94, then once we reach the 95/98 in locked 4th would see the temps up to 96 @ 2300rpm but would spike quickly to a high of 97.7 if revs slowed to 2000 doing around 90kph.
I have no Egt gauge but suspect the temp gauge antics are caused by the Egt’s, I realise at those temps no damage is occurring but I’d rather be watching the road than a Nanocom.

My cooling system is in perfect condition but I do have 2 spoties in front of the grille which probably is not helping, this is the first small bore alloy head Td I have owned so it’s also a big learning curve for me and my brain is no help either.

I just towed with my tuned manual disco, was towing another disco on an trailer, head temp was 98 at the highest at 105kph and etg 500-600 and with 20Psi boost

Was really impressed with the performance and map from Td5inside

Egr and decat will help but i dont think it will help too much with the temps you are getting which are on the high end .

Im still on a standard tune but run a decat , Main muffler delete and a egr delete also have a Hybrid turbo and a seck intercooler .
Last longish trip i did was to Cooma for the 70th and i was 4240 kg car and camper and the highest egt i saw was about 600.
By the way i have a SaaS Egt Boost gauge which has a alarm for both that sound and the light flash`s .
You can preset your max Egt and Boost and dont stress about having your eyes peeled on the gauge

Originally Posted by Leo109

As soon as the load goes up (moderate hill) the EGT rockets up at least twice as fast as the old 300Tdi (well fuelled-up). It would rocket past 700 C and a couple of times exceeded 760 C before I caught it. And the reason I was repeatedly caught out early on is that the throttle was nowhere near WOT at the time. The vehicle seemed to be doing it fairly easily on part throttle when I'd glance at the EGT and see alarming numbers! .

Watch the boost too cos if it's not the best you can increase it to max allowed by shorteing the wastegate rod or using a MBC then the EGT will drop a bit.... IMO 760 spikes with heavy trailer uphill might not be scary as long as it drops while cruising on motorway to around 400

I'm currently towing my 3+T semi off road brick checking out the wildflowers in mid WA with my MY04 D2a TD5. It is reasonably flat country by eastern states standards (no mountains).
In the morning the beasts radiator (aluminium) sat on 94 celcius and 550/600 EGT at around 80/83 kmph. Later in the day at 30 celcius ambient, went up to 98 coolant on the Nanocom. Realistically, I can't cruise at much more than 80, except downhill. We won't talk about the hills, except to say that I regularly have to use 2nd and as low as 60kmph to keep the EGTs below 650.
Of course I also cruise on the flat in 3rd sport mode (and 1st to start off) as both advised/recommended for heavy towing many times on this site.
In addition to a slightly oversize alum radiator, I have a mild TD5Inside remap, Serik intercooler, auto trans additional front mounted cooler, Ashcroft type torque converter, Provent and de-EGR'd, but also 2" lift and 31" tyres just to make life difficult. So far this trip I'm averaging 18L/100 km in lieu of normal 12+ L/100km.
Definitely at the higher end of this machines towing capacity, but hell, who's in a hurry!!!
Cheers

if your egt's are getting that high and you want to drop them the cheapest way would be to get water spray onto the intercooler to reduce intake temps, next would be to get a water/methanol injection setup going in the intake.

An intercooler upgrade will help depending on how much extra heat a larger intercooler can remove, but from what i have seen the upgraded intercoolers are not much larger then a d2a one so my guess is maybe 10-20deg intake air temp drop at WOT with full boost.
A larger turbo or at least a larger compressor wheel would prob help more so as the air wont of been worked as hard to get the same pressure which will mean less heat for the intercooler to remove

Changing the flex joint to something less restrictive would do as much as a the decat, so fitting an earlier d2 engine pipe will help heat get out.

at WOT the egr does not work so removing it wont reduce exhaust temp other then just by removing a passage for exhaust to go and stop.
at throttle applications where the egr works it will actually run a cooler exhaust temp as that's is one reason they run egr n diesels for is to have a cooler combustion event when running lean to reduce nox emission's.

Cant sat for certain on the tune aggressiveness but sounds like a std increase the fuel with a slight boost increase which is fine when going single but can cause issues with towing.

also your temp issues can also be because of not being at wot with the tune as it may be limiting the amount of boost, less boost with lots of fuel is more heat

I would also remove all impediments to cooling although I have to say IMHO there is little correlation between engine temp and EGTs.
As I said, I have cut out my grille and fitted 70% void mesh, as if it is good enough for Saudi spec , it must do something.
My engine temp rarely exceeds 85-88C but I can get 750 EGT on hills. I often wonder whether at high throttle openings whether the EGT is overstated due to the short distance between the ports and the EGT probe. My manifold is also ceramic coated so would keep the heat in.

BUT really , you are pushing it with a plus 3tonne caravan. My camper trailer weighs 1000Kg fully loaded with 2 jerries of fuel and 60 litres of water.
Regards Philip A