Yet another EGR disposal thread

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Originally Posted by Slunnie

Gday Dave, love your work!

Question though.

When I did my EGR system, I did it by unplugging the EGR only and seem to have found similar gains - of course this is judging by the conclusive seat of the pants o meter. Low/mid revs and light throttle gains were the most apparent and anything else with a bit more "stick" felt the same.

I guess the question is, what are the gains to be made by removing the EGT system or by physically blocking the system only in comparison to just unplugging it?

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yep providing your valves arent leaking you will notice the same difference by just letting the system not open them when it wants to. on mine the crud built up on the seat of the valve and was letting a little exhuast gas in all of the time.

I also get a marginal flow increase as I dont have the valve and the butterfly in place to obstuct the flow.. an interesting side note as I found out today I have a slightly better engine retardation which Im putting down to the butterfly not closing off when Im off the noise and slowing down. I wouldnt call it as good as an exhaust brake but (new thought) its noticabely better than it was.

(new thought) funny but that butterfly looks susly like an exhaust brake valve... I wonder............

edit

Before you all get to me on it..

YES Im aware that Ive got a pic of the EGR replacement bypass tube instead of the EGR as the clean before pic but i didnt think to take a pic of it when I was cleaning it
endeit

Cool. A good point re the EGT valve. I've got no idea if mine is leaking.

When I removed and cleaned mine it was obvious the carbon on the seat wasnt allowing it to shut properly.
I blanked the vacuum line and got much better driveability.
Have the EGR replacement kit on standby.It will get done when I fix all the other issuse that are starting to become a LONG list.
Andrew

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Originally Posted by BradM

That's great Dave! All you need to do now is add an ECU Fuel Remap (TR does an absolute ripper but stills keep it within tollerable limits for the TD5) and remove the existing muffler and replace it with a Vortex one.

These three modifications courstesy of TR's knowledge work really well together and once done, you will unleash "The Beast" that lurks within your TD5.

About 30%+ more power with same fuel economy and the best idle you have seen and heard on a TD5.

Who knows you may even want to then head over to WillowBank to give it a try out. :)

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Improvements to be had by removing the hyclone in the airbox too, assuming it has one like the D2.

Brad,
Did you get a ready-made replacement exhaust section with the Vortex or did it have to be made-up?
Thanks,
Graeme

and what about the crankcase emission control?
Can we do something constructive with the breather valve, and/or re-direct the hose?

I do not think it would do the bore or rings much good feeding in valve grind paste plus it would get into the oil. I wouldn't reccomend it.

I bought a Vortex muffler on TombRaiders reccomendation as he had one fitted on Lara and had the origional muffler cut out, then the Vortex welded in it's place (My welding is terrible).

I still have the Cat converter on MY2003 and the origional rear resonator. I was going to remove them but my fuel economy returned back to where it was before the EGU Remap so I thought "why bother" as I have all the power that I need now.

Did a trip to Perth and back about a month ago, 3,500 klm and now when you floor it to overtake roadtrains you need to keep an eye on the tacho as it revs up so quick. 10 l a 100klms sitting on 110 klms going down and 10.8 l a 100klms sitting on 100klms coming back towing a boat.

My wife's comments were, "If you wanted a V8 why didn't you buy one" instead of Hotrodding the poor deisel. :):)

I went for the ECU Remap first and then really noticed the extra that the EGR removal and vortex muffler added as I did it in 3 steps to make sure all was OK.

Along the way I had to deal with a faulty MAF and tired fuel pressure block. New ones of these also added much Zing to the setup.

Also I have my turbo wastegate adjusted fully closed at idle so that I get max boost all through the range before the ECU starts tickling the modulator for the control of the wastegate arm.

"Absolutely No Problems" all Good

BradM

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Originally Posted by Nicky

and what about the crankcase emission control?
Can we do something constructive with the breather valve, and/or re-direct the hose?

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on the cooker for research..

other things that went onto the cooker...

capturing the output air from the vac pump and using that to pressurise the breathers preventing water ingress.

bleeding off of the inlet manifold into a 2l co2 bottle with a 2psi pressure regulator and one way valves for same

using the EGR as an exhaust brake on kermit

using the EGR cooler as a water heater (plans are looking like a double exchange system will be set up with the storage heater in the wing and hot water on demand coming from an additional storage tank... Storage system will be plumable for showers and non pot water heating and a demand flow will be made up for hot drinking water.)

install 3 soda stream CO2 bottles under the right wing as an in engine bay fire fighting system and emergancy shut down

modding the EGR unit to allow it to function as an emergancy shut down valve.

the idea hamsters only just got started with this one.