EGR Blank on 08 TDV6

**Graeme** · 22nd April 2012, 07:57 PM

I've discovered that one of my sons has spent considerable time over the last few months working away at reverse-engineering a Bosch ecu from a twin-spark VVT Alfa motor about which there was very little known other than some of its spark and fueling tables (maps). He's about 50% through the code and finding previously-unknown parameters that if modified could make quite a difference to the performance of these engines for both road use and for racing. He has also discovered that the code in quite different Bosch ecus for quite different vehicles all have very similar structure. I'll get hold of a 2.7 TDV6 ecu dump to see what he can find in the way of EGR parameters. EGR may be able to be disabled by setting an activation parameter to an unobtainable value (eg changing the minimim coolant temperature to 200 degrees) but that requires that at least the appropriate part of the ecu code needs to be understood, not just labelling tables/maps so quite a lot of work likely to be required. Now, where's a 3.0 ecu dump?

**~Rich~** · 22nd April 2012, 08:01 PM

Jeeze Graeme interesting stuff!
I know of motor vehicle wreakers but unsure where to find a ecu dump.

**Graeme** · 22nd April 2012, 08:27 PM

There are lots of ecu dumps - just have to know where to find them!

I have yet to ascertain if 2.7 ecu updates are just specific address ranges or the whole ecu but a whole ecu hex file is required. I grabbed an unidentified Rover ecu map file from the Faultmate libray on my PC which was found to be for the whole of a Bosch ecu, so maybe I just need to identify a TDV6 one. The 80+ tables were found in seconds and my son expected to be able to determine the use of more than half of them within 30 minutes from what he already knew from other Bosch ecus and the data values.

**Dougal** · 23rd April 2012, 05:36 PM

Graeme, which software is your son using?

**Graeme** · 23rd April 2012, 06:49 PM

He wrote a program which, if I understood correctly, finds all tables and then uses an ecu editor to dissasemble the code allocating generated labels to everything. Useful labels can then be applied to the tables, routines and variables etc, along with adding comments to every line of code as he unravels it. The editor also heirarchically links all called routines, ie flowcharts the entire program. I don't know if the dissassembly program is generally available or provided to him by someone interested in the results.

Ean Austral · 23rd April 2012, 07:02 PM

Sounds like mumbo jumbo to me , but am sure you guys know what the hell you are talking about..

As a matter of interest , no faults have been logged since the orignal fault was logged.

Cheers Ean

**Dougal** · 23rd April 2012, 07:11 PM

Originally Posted by Graeme

He wrote a program which, if I understood correctly, finds all tables and then uses an ecu editor to dissasemble the code allocating generated labels to everything. Useful labels can then be applied to the tables, routines and variables etc, along with adding comments to every line of code as he unravels it. The editor also heirarchically links all called routines, ie flowcharts the entire program. I don't know if the dissassembly program is generally available or provided to him by someone interested in the results.

Good to know, thanks.
I know people who have dis-assembled ECU code, but I haven't done it myself. I have need for such a service on some comparitively very simple diesel ECU's I have here on an engine I'm modifying. I have the ECU dump as a binary file, PM me if he is willing to take a look.

Ean Austral · 30th April 2012, 06:06 PM

Gday All,

Well the car logged the fault again today, Its fault code P0402 excessive EGR flow detected, the car goes into limp mode and the dash lights up with what in a D2 would be the 3 amigo's.

Turn off the car, restart and all good, cleared the fault with hawkeye, and see how it goes. The fault occured as SWMBO was slowing down to stop at the lights.

Just need to decide if a fault every 3 weeks or so is worth the trouble or just re-fit the EGR system. If I think of the amount of krud in the inlet side, clearing a fault seems like the best option.

Cheers Ean

**Graeme** · 30th April 2012, 06:31 PM

If you decide the faults are too inconvenient so need to re-enable EGR, why not put the butterfly back as the 1st step and try that for a while? It might save someone else the trouble of fitting only the plates to see if that triggers any faults.

Ean Austral · 30th April 2012, 07:10 PM

Originally Posted by Graeme

If you decide the faults are too inconvenient so need to re-enable EGR, why not put the butterfly back as the 1st step and try that for a while? It might save someone else the trouble of fitting only the plates to see if that triggers any faults.

I did think of that, but my simple mind tells me that the butterfly closing and no airflow coming to the intake side will stall the engine, or cause it run very rough. I may not understand the EGR system completely, but again my mind tells me the butterfly is there to close off the air, and when that happens the EGR valves open and exhuast gas enters the inlet side and compensates for the air intake thats blocked by the butterfly.

But sure for the time it takes it will be an easy excersise.

Cheers Ean

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