EGR blanking plate to block off or restrict?

[Dingle Lurker Find all posts View Profile Close Dingle]

FYI I just completed a 6000km trip Brisbane - Birdsville via the Warrego Hwy- Birdsville track to Flinders ranges - Old Strezlecki track to Innamincka - Brisbane via Adventure way. This was towing a 1.5 ton camper.

Before leaving I installed a EGR plate with a 5.5mm hole and it threw no codes through the trip. All good. Hopefully it'll stay that way.

Mines a 2014 Facelift GXL, 30,000Km, DP chip (default setting), no exhaust changes.

Hope this helps the collective.

[zakman Lurker Find all posts View Profile Close zakman]

Hi,

Found this on another website regarding D4D EGR info & copied below so I hope I don't infringe any ones copyright as it has interesting info I feel need's to be shared. I am sure other members would be interested in feedback & comments to follow.


Hi all

I have done another basic description on the EGR system of the 1KD D4D engine & this does NOT apply to the 1KZ mainly due to the Turbo & EGR configuration.

May I also add that i did not do this write-up to start an argument but to let those who are not fully mechanically minded to have a better understanding.

On the 1KZ engines the turbo has a mechanical waste gate attached to the external of the turbo which is operated by manifold pressure and independent of the EGR system so when you block the EGR port everything runs happy (Better) and no more EGR gases are pumped into the intake manifold and you get to run the engine on nice clean air and boost pressures are not provoked.

If you block or restricted the EGR system on the 1KD D4D engine by fitting a blanking plate you will inadvertently increase fuel consumption (Worse) and cause loss off power backed up with an engine check light with error code

You can get rid of the error code by drilling a whole in the middle of the banking plate (10mm) which will stop the error code but you will still cause issues globally due to the restriction of the turbo boost dumping process!

REASON: The 1KD has a variable high press turbo which is mechanically adjusted via an electronic solenoid which is solely controlled by the ECU (Electronic Control Unit) to improve the spooling of the turbo depending on engine rpm.

IF this doesn't make things harder to by-pass the EGR system then what follows will! The 1KD does not have a simple system like on the 1KZ's but rather a system where the turbo boost is sent BACK through the EGR cooler on the same path in-order to dump the access turbo boost back into the exhaust. (EGR valve in the intake throat opens to let exhaust gases in but also opens to let access turbo boost out).

Depending on engine load the access turbo boost needs to be dumped immediately. If this is not accomplished then the turbo boost will hang around in the intake manifold and inter-cooler which will cause a leaning off (Weak Mixture) in the combustion chamber and the boost that is trapped will back-flow back into the inter-cooler then pushed through the air filter box in order to escape. This will also put the dirty air and EGR gases across the MAF (Mass Air Flow) sensor. This will also be recognised by the turbo sensor located on the turbo inter-cooler which will be sent to the ECU and will in-turn drop the fuel rail pressure to try and reduce the access boost that has been trapped!

OUTCOME: Even though the car will drive "ok" it will feel doughy at the pedal and feel like you are driving in a head wind and your fuel consumption will get worse not better.

I know that this whole principle of the 1KD sux but apart from being stuck with EGR gases it is a very officiant principle.

OPTIONS: If you want to reduce the fouling of the intake components the only best option at the moment (Until someone develops a chip to disarm the EGR gas flow but still allow the EGR valve to operate to dump access boost) is to fit a PCV (Positive Crankcase Ventilation) filter or catch-can to at-least reduce oil mixing in the intake manifold which is made very sticky when EGR gases are blown across the oil.

The cooler housing for the EGR does not only cool EGR gases but has a simple switching mechanism which is controlled by a vacuum canister that closes one port and opens another simultaneously when dumping turbo boost.

Blanking off this vacuum line does not effect turbo dump as it just back-tracks through the port that is open as both ports are linked together anyway! One side is cooled by the engine coolant for the hot EGR gases and the other is just a straight through port for dumping access boost.

PS. Hint! I basically mean to say Do Not Block EGR port with a blanking plate on 1KD D4D.

Hope this has made a few things clearer for some one who is thinking of fitting the blanking plate on the EGR on the 1KD D4D.

[winniliss Avid PP Poster! Find all posts View Profile Close winniliss]

I have done the full block and have done about 3000kms. More than happy with the results and engine doesn't feel like its lacking. I change gears through the nominated torque range of 1500 - 2500rpm and have had no error codes. I am running the manual mapper.

[Coolcol Moderated member Find all posts View Profile Close Coolcol]

Hi All, I have a restrictor (7 mm hole) plate in and the fuel economy has not changed. The low down acceleration has improved (after clean and restrictor) and 10K after fitting the plate the EGR valve is still clean and showing no signs of fouling up again. So I'm happy!
Colin

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Hi,

Found this on another website regarding D4D EGR info & copied below so I hope I don't infringe any ones copyright as it has interesting info I feel need's to be shared. I am sure other members would be interested in feedback & comments to follow.


Hi all

I have done another basic description on the EGR system of the 1KD D4D engine & this does NOT apply to the 1KZ mainly due to the Turbo & EGR configuration.

May I also add that i did not do this write-up to start an argument but to let those who are not fully mechanically minded to have a better understanding.

On the 1KZ engines the turbo has a mechanical waste gate attached to the external of the turbo which is operated by manifold pressure and independent of the EGR system so when you block the EGR port everything runs happy (Better) and no more EGR gases are pumped into the intake manifold and you get to run the engine on nice clean air and boost pressures are not provoked.

If you block or restricted the EGR system on the 1KD D4D engine by fitting a blanking plate you will inadvertently increase fuel consumption (Worse) and cause loss off power backed up with an engine check light with error code

You can get rid of the error code by drilling a whole in the middle of the banking plate (10mm) which will stop the error code but you will still cause issues globally due to the restriction of the turbo boost dumping process!

REASON: The 1KD has a variable high press turbo which is mechanically adjusted via an electronic solenoid which is solely controlled by the ECU (Electronic Control Unit) to improve the spooling of the turbo depending on engine rpm.

IF this doesn't make things harder to by-pass the EGR system then what follows will! The 1KD does not have a simple system like on the 1KZ's but rather a system where the turbo boost is sent BACK through the EGR cooler on the same path in-order to dump the access turbo boost back into the exhaust. (EGR valve in the intake throat opens to let exhaust gases in but also opens to let access turbo boost out).

Depending on engine load the access turbo boost needs to be dumped immediately. If this is not accomplished then the turbo boost will hang around in the intake manifold and inter-cooler which will cause a leaning off (Weak Mixture) in the combustion chamber and the boost that is trapped will back-flow back into the inter-cooler then pushed through the air filter box in order to escape. This will also put the dirty air and EGR gases across the MAF (Mass Air Flow) sensor. This will also be recognised by the turbo sensor located on the turbo inter-cooler which will be sent to the ECU and will in-turn drop the fuel rail pressure to try and reduce the access boost that has been trapped!

OUTCOME: Even though the car will drive "ok" it will feel doughy at the pedal and feel like you are driving in a head wind and your fuel consumption will get worse not better.

I know that this whole principle of the 1KD sux but apart from being stuck with EGR gases it is a very officiant principle.

OPTIONS: If you want to reduce the fouling of the intake components the only best option at the moment (Until someone develops a chip to disarm the EGR gas flow but still allow the EGR valve to operate to dump access boost) is to fit a PCV (Positive Crankcase Ventilation) filter or catch-can to at-least reduce oil mixing in the intake manifold which is made very sticky when EGR gases are blown across the oil.

The cooler housing for the EGR does not only cool EGR gases but has a simple switching mechanism which is controlled by a vacuum canister that closes one port and opens another simultaneously when dumping turbo boost.

Blanking off this vacuum line does not effect turbo dump as it just back-tracks through the port that is open as both ports are linked together anyway! One side is cooled by the engine coolant for the hot EGR gases and the other is just a straight through port for dumping access boost.

PS. Hint! I basically mean to say Do Not Block EGR port with a blanking plate on 1KD D4D.

Hope this has made a few things clearer for some one who is thinking of fitting the blanking plate on the EGR on the 1KD D4D.

You are not the first to copy & paste that.
When there are varied opinions people need to choose who to listen to.
Although there is some facts in that post, it is full of wrong information.

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Hi All, I have a restrictor (7 mm hole) plate in and the fuel economy has not changed. The low down acceleration has improved (after clean and restrictor) and 10K after fitting the plate the EGR valve is still clean and showing no signs of fouling up again. So I'm happy!
Colin

Typical although many report better fuel economy.

[Grumpy Junior Member Find all posts View Profile Close Grumpy]

Dropping the oil every 5000k's and finding it still clean tells me I made the right decision to fit the 7mm plate. I've done 15000k's since manifold clean & EGR restrict with no signs of fouling. Can't say I've noticed any difference in fuel economy.

[Wildfire Lurker Find all posts View Profile Close Wildfire]

Hi guys, I'm new on here and want my 2016 gxl 2.8 to last the distance. With the egr, can this be electronically taken out of the equation when doing an ecu remap and tune? I've only done 1500kms and love the prado! Great on fuel for a rig of its size!

[Benlux Find all posts View Profile Close Benlux]

I got my 3L done last week and I spoke to the guy they haven't cracked the Ecu on the 2.8 yet.

[Wildfire Lurker Find all posts View Profile Close Wildfire]

Yeah I think you're correct there, I was just told it might be a few more months for the 2.8 to be cracked. How is the 3L now? Is there a big improvement?

[Benlux Find all posts View Profile Close Benlux]

It's a lot more responsive , u can definitely hear turbo spool up now. I haven't had a chance to go for a descent drive as yet.

[Nova Member Find all posts View Profile Close Nova]

Got my EGR plate fitted today, took a while, although I probably spent a hour of that hunting around for spanners and sockets that fit properly. There is not much room to get at some of the bolts up near the firewall. Ratchet spanners are a godsend, as are socket extension bars that allow some angle of the socket. I was surprised how much black crud was in there with 26000km on the clock. It was all pretty soft though, came out pretty well.

Did a quick run into town (20km return) but didn't really notice much difference. Got a 200km trip tomorrow so we'll see then. Hopefully it'll help keep it cleaner and last longer without clagging up.

Cheers, Nova

[Wil Senior Member Find all posts View Profile Close Wil]

Is the step by step instruction for fitting a restriction plate that is listed on the ozbush website suitable for use when installing on a 2014 facelift update prado?

[Buts Lurker Find all posts View Profile Close Buts]

is there any instructions around on how to install on the 1GD

[JimmyC Advanced Member Find all posts View Profile Close JimmyC]

I know this is in Russian but the visual aspect seems helpful:
https://www.youtube.com/watch?v=Jk63HaWbzw4
https://www.youtube.com/watch?v=BWjRGxkTV6w