Blocking the EGR Valve

[spacekadet]

cheers timbo, just went out and blocked my EGR, template was a good start. This is my first engine mod i have done, and it works fine, so im stoked.

good luck to the rest.

Tim

[YNOT]

Welcome to the forum Spacekadet, drop by the intro thread when you get a moment and tell us a bit about yourself and your Patrol.

Tony

[tonejack0]

Thanks Tony but still cant get my head around this.

[tonejack0]

Hi all I’ve posted in the past that I melted my number 2 piston, ( 2001 3L Dti ) but it’s all back together now and I’ve just taken it for a short test run. I have cut the CAT out from the down pipe and blocked the EGR valve and fitted a boost gauge, but I understand from reading the posts there are more mods to do before it’s safe to use.
I’m not able to download the Aksness manual as I’ve only just joined and not posted 25 posts yet.
I don’t know how to adjust the boost.
Also can you tell me what it’s like to drive in limp mode, does it just go very slow? Does anyone do a pod to take the boost gauge and a volt meter?
It’s cost over £3000 so far and if it goes again I don’t know what I’d do, I feel it’s an untrustworthy engine now. It had only done 56,000 miles and I’ve not done anything to stop this happening again.
It’s really nice here in the UK today 3 degrees C and diesel just gone up to £1.30 L

Tony J

[RustyNails]

Just blocked my EGR (thanks for the plate Ferret) but have yet to do the butterfly valve.
So thoughts so far are
- It does not seem to have any more power but it definately runs smoother and the turbo lag seems to be reduced
- Definate BIG reduction in the amount of smoke
- Seat of the pants fuel economy seems to have improved also (need to run it through a few tanks and check the figs to confirm though)

Only issues I had was I assumed that the plate would go in from the top but it wouldn't, so had to add it from the bottom. And wanted to add the plate between the gasket and manifold but couldn't as the gasket has a sleeve running inside the manifold that prevented the plate fitting.

Paul

[the ferret]

Just blocked my EGR (thanks for the plate Ferret) but have yet to do the butterfly valve.
So thoughts so far are
- It does not seem to have any more power but it definately runs smoother and the turbo lag seems to be reduced
- Definate BIG reduction in the amount of smoke
- Seat of the pants fuel economy seems to have improved also (need to run it through a few tanks and check the figs to confirm though)

Only issues I had was I assumed that the plate would go in from the top but it wouldn't, so had to add it from the bottom. And wanted to add the plate between the gasket and manifold but couldn't as the gasket has a sleeve running inside the manifold that prevented the plate fitting.

Paul

Hi Paul, you should find that it spools up about 3 to 400 rpm quicker, quieter, and some say better fuel economy, I havn't seen any proof regarding better fuel economy.
If you remove the two nuts holding the EGR, and then spring the EGR away from the manifold by about 20mm, the plate will drop in with a bit of jiggling.
The plate is best placed between the EGR and the gasket, this way there is less risk of sucking dust into the manifold as it will be sealed by the gasket and plate.
If you add 2stroke to your fuel at 200 to 1, the motor will run even quieter and I have found a fuel saving using the twostroke.
The butterfly is easy to remove, while you have the intercooler off, give it a good wash out and dry as well as the 2 intercooler hoses.
I think you ought to have another go at it and get the gasket against the manifold as your plate is exactly the same as mine and it's been in and out about 6 times.
Cheers Rod.

[YNOT]

Just on the 2 stroke oil, if I remember correctly from other threads I've seen on the subject, use mineral based oil not synthetic.

Tony

[the ferret]

Castrol 2t active is the go I believe.

[RustyNails]

Hi Paul, you should find that it spools up about 3 to 400 rpm quicker, quieter, and some say better fuel economy, I havn't seen any proof regarding better fuel economy.
If you remove the two nuts holding the EGR, and then spring the EGR away from the manifold by about 20mm, the plate will drop in with a bit of jiggling.
The plate is best placed between the EGR and the gasket, this way there is less risk of sucking dust into the manifold as it will be sealed by the gasket and plate.
If you add 2stroke to your fuel at 200 to 1, the motor will run even quieter and I have found a fuel saving using the twostroke.
The butterfly is easy to remove, while you have the intercooler off, give it a good wash out and dry as well as the 2 intercooler hoses.
I think you ought to have another go at it and get the gasket against the manifold as your plate is exactly the same as mine and it's been in and out about 6 times.
Cheers Rod.

Thanks Rod

Yeah have got it between the gasket and valve, the sleeve on the gasket stopped me from adding it between gasket and manifold.
Was reluctant to take the nuts off completely (and then drop something and never find it again) but no matter what I tried it wouldn't go in from the top, will try again when I do the butterfly.
BTW when I do the butterfly do I need to do anything to the vacumn hoses?

It has only been on a short while but I am not sure if the boost comes on any earlier (perhaps marginally) but it does come on smoother without the huge amount of lag I have had. Definately a lot less smoke (mine is a real bad smoker) with that aspect alone worth the $25. As I said I feel as though the fuel economy is better, just need to empty the tank a couple of times and check the figs. Did a run from Whitehills Bch to Preston Bch and the trip home from Mandurah-Perth with the camper on the back and the Kayaks on the roof and used stuff all fuel (less than a quarter) where the run home from Mandurah is usual worth a third of a tank on it's own.
Got to do the butterfly this week and will try the two stroke too.
Thanks

Paul

[the ferret]

Yep, you have the plate the correct way if the gasket is at the inlet manifold.
With the vacuum hoses, I just put them all back, they won't do anything even if the ecu tells em to, as there will be no butterfly, the ecu will think its the boss, ha ha.