Yet another EGR disposal thread

[Blknight.aus]

ok big red is now sans EGR, watch this space for an update with pics and a pdf how to including the tools needed to do the job.

took me 2 hours but I had to stop every step of the way clean my hands take a pic and keep going.


MY initial thoughts...

Yep do it.

Big reds boost comes on in a much more linial fashion. She used to build up to 5 or 7 psi then lag a bit then steam up to full boost like there was no tomorrow. Now its like all the beurocracy has been removed from between the loud pedal and the boost gauge. WInd the knob up on the volume and instead of getting the officious "yep heres what Ive got ready and I'll give you some more later" answer its now more akin to "hello turbo speaking. yes MR right boot? oh you want boost? sir its being delivered as we speak"

other cool things

where I used to cruise around with 7-8psi indicated I now cruise around with 6-7psi indicated, remember my boost gauge is hookedup pre intercooler and not on the inlet manifold. to me this says that the air is flowing into the engine in a more effecient manner.

ID love to say theres more power, but well there isnt, the volume control still only goes to 10. Ditto for overall acceleration over the normal test track from standing start to run a given distance only about .5sec difference, better yes but then it was also some 8 degrees cooler so inconclusive at this point but its much nicer to do

the shudder after long engine braked decellerations is also gone.

AND Ive nutted a way of using the EGR heat exchanger as a water heater, Mine will be used for non potable water for showers and the like but put a new one in place and I see no reason it cant be used to bring water to nearly boiling.

[spudboy]

Will be interested to see how you make the EGR bits heat water!
Cheers
David

[Captain_Rightfoot]

good work... waiting for pics

[Pedro_The_Swift]

will it be a TUTORIAL Dave?

[Redback]

All his posts are tutorials Pete, must drive the spelling and grammatic police bonkers

Baz.

[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.

[MickG]

Considering this mod so watching with interest

Aye, Mick

[Blknight.aus]

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.

as indicated eleswhere in other threads I 've a fair idea how much is left in reserve in the Td5 but Im a little pedantic on how I rebuild and mod engines....


the ECU rebraining is on the cards BUT first the engine is going to breath correctly with the current ECU Today saw me doing a lot less work than normal and using big red as the workshop runabout... All my thoughts and previous indications are confirmed... a couple of guys whove ridden in big red before are impressed at the better low speed boost rate that she now has.

I Chock loaded the tank last night and again today after work and it appears that on a single days drive that fuel economy is up about 1k/l but again its been cooler today that it has in the past. This puts the fuel economy back to about where it was when new so my feeling is that my EGR valve was never closing correctly. I also cannot get the engine to shudder at idle after engine braking and I tried everything short of putting a thong on the intake.

When I wade through the rest of the new posts I will ammend the pics of the before after and the cruddy condition of the EGR unit which has done less than 3K Km since i cleaned it as part of the 100K Km service.

[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?

[Blknight.aus]

ok before i do up the thread on how to heres WHY to.


when I started the 100K Km service I cleaned out the EGR assembly... i bought it back so it was as clean as the guts of the new thingy I just installed....

PA170084.jpg

see purdy and shiney....

Heres how it is less than 3K km later...

PA170081.jpg
PA170082.jpg

loverly oily carbony sooty build up..

Just a thought, Last time I needed to lap a valve I used some charcoal and a little engine oil.... did a stirling job of abrading the faces to suit each other....

while Im thinking.....Ive got a question.

Would you pour valve lapping paste into your engines air intake manifold while it was running?