EGR the plot thickens, as I have plenty of time on my hands ( relaxing in the Gambian sun lol) I dropped a quick email to those nice people at Ozbush electronics.
This was my question
Hi I'm interested in your EGR blanking system,
With a 2001 1kd-ftv 3l Diesel engine can I blank the EGR with no hole? If so we're dose the turbo dump dump its excess pressure to?
Andrew,
And there reply
Before we rush into any further, could you find out one thing?
Please take look at the engine and locate the EGR valve.
Is your EGR valve has EGR vale position sensor attach to it?
You can use our Manual Mapper if you have the EGR valve position sensor. It is a triangular looking piece with 3 wire connector.
I have a photo attached in this email.
Our system is using full blanking plate without any hole. And using EGR valve position sensor the Mapper will simulate EGR condition precisely so the car computer thinks all is fine.
You can also do the minor fuel trimming so you can tune your engine a bit.
The EGR valve is not used as a turbo wastegate dump, Hot and fiery pressurised exhaust gas will flood in to the inlet manifold every time EGR valve is open without exception.
By the design, diesel engine do not require waste gate, the cylinder piston is the wastegate system.
All it takes to turn crankshaft once then all the pressure is released. Diesel has no throttle body, no premixed fuel or spark plug there is no any danger for pinging or backfire.
Some diesel do have turbo wastegate but it is for maximum rpm limiter.
The turbo pressure control is very easy in diesel engine, unlike petrol engine.
I have a file attached to this email for you to read.
Thanks
Young
Ozbush Electronics
EGR Gas Cooler that Kills Engine like Flies
ooler that Kills Engine like Flies
Fallacy of the EGR Emission system.
Everyone pays attention when the fuel pump or injector problem arises which can be very important for the welfare of the engine.
But nobody seems to care about EGR gas cooler being a ticking time bomb.
The EGR system stands for Exhaust Gas Recirculation to control the city smog gas that is Nitrous Oxide gas (NOx) which generated by full temperature diesel combustion.
The earth's atmosphere contains a large amount of natural Nitrogen gas (78%) and Oxygen (21%) as the dominant contents of air which we breath.
So the proper full temperature diesel combustion naturally produces NOx gas, but it causes light yellowish exhaust gas which we called city smog. But I don’t think it is really that harmful to human health compare to what comes out of half burnt fuel with EGR. The lowered combustion in diesel engine produces so many harmful carcinogenic substances (cancer causing gases) the city smog gas is not so harmful considering what the EGR system produces.
To lower the smog (NOx), EGR system has been invented since 1970s on petrol engine and I might say it was very successful.
The idea behind is, to reduce the NOx emission they choose to lower the combustion temperature by recirculating part of the exhaust gas back into the inlet to interfere full combustion so the Nitrogen gas will not have a full chemical reaction to cause NOx gas.
In petrol engine they only need minute amount of exhaust gas to recirculate to achieve the level of NOx gas therefore they didn’t need to cool down the hot exhaust gas.
However, in diesel engine due to high compression, they needed a large amount of exhaust gas to recirculate (up to 20%) to achieve the same level of NOx gas emission.
You can’t just recirculate such large amount of hot fiery exhaust gas straight into the inlet without causing many other issues and they needed to be cool the gas down to acceptable lower temperature.
The EGR gas cooler is a device which cools very hot fiery exhaust gas before they feed into the inlet manifold. The engine coolant is used to cool down the hot exhaust gas and this gas cooler will be corroded (burnt) as it encounters the fire daily.
It starts to leak engine coolant very slowly into the inlet at the fire front side section and the driver would not
know what is happening because the whole symptom is so insidiously slow and gives no indication unless you check the coolant level every day.
Then one day it will suddenly go into full blown coolant leak and by the time you realised that there is something is going wrong, it is usually too late.
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