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Manual Mapper Project for Toyota Diesel Engines

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  • #31
    Good to see you on here Ozbush, and the development you have done so far. Will see how the 2 units go and will send you another email to purchase one.

    Cheers Derek
    Blue Storm 150 GXL 4D4 PRADO and 2014 Cub Brumby Camper My rig build [url]http://www.pradopoint.com/showthread.php?25698-Derek11-s-2012-Blue-Storm-150-GXL-build-up[/url]

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    • #32
      Originally posted by derek11 View Post
      Good to see you on here Ozbush, and the development you have done so far. Will see how the 2 units go and will send you another email to purchase one.

      Cheers Derek
      Hi Derek
      Good to see you.
      Have you fixed your car problem or just bought new car?
      I hope I am talking to Derek11.
      If so I would like to know what was the problem, I recon it was faulty ECU with Auto trans.
      Ozbush

      Comment


      • #33
        Originally posted by groeschel View Post
        Hi Ozbush,
        if you need a local truck to have play with and to check to connectors give me a buzz.
        I am local to you and running a blanked EGR since years on my 2007 D4D (and ignore the MIL light ;-) 0
        I send you a PM with contact details.
        Cheers
        Mike
        Hi Mike,
        Thanks for all of that and phone call.
        It's good to have a person so nearby with full blanking plate and suffered for years of MIL.
        Yes we get together and install our mapper and see how it goes.
        Let me know when you are free.
        Thanks
        Ozbush

        Comment


        • #34
          Originally posted by Rusty62 View Post
          Fitted Ozbush mapper unit today. Full blank plate installed. So far so good with no alarms after 10 minutes. Will need to do a longer run to confirm no alarms.
          Interestingly the Hilux and Prado have different coloured wires to the EGR sensor. Not sure if the EGR sensor is a different part number.

          Hilux.




          Prado.



          Rusty.
          Argh nice work rusty,

          Did you run it with full blank plate in first to see if it got a mil?
          Would have been interesting, because some don't.

          Good to hear so far so good!

          Comment


          • #35
            Originally posted by Ozbush View Post
            Hi Anthony,
            A month ago, I burrowed my friend's almost brand new Hilux with 1KD-FTV engine in it and still under new car warranty.
            So he wouldn't allow me to install the blanking plate but I did play around other stuff.
            I did install my mapper unit in the Hilux and I was hoping to see what ambient temp would shut down the EGR system like any other diesel EGR system in the world. I was playing around IAT (intake air temp) sensor in the MAF to see EGR shutdown but it never happened.
            Toyota car computer would simply enable EGR all the way from -35c to +80c and never saw EGR shutdown.
            All other diesel cars in the world do shutdown EGR system at below certain temp (around +5 to +10c) such as Mazda/Ford, Honda, Mitsubishi, Holden/Isuzu, Jeep, VW, Audi, and Benz but not Toyota.
            So I was forced to abandon the IAT shutdown mode and concentrate in EGR emulation mode with blanking plate only for Toyota.
            My friend wouldn't let me touch the car mechanically due to warranty. I couldn't try blanking plate.
            So here I am looking for volunteers who don't mind playing around a bit.
            Cheers mate.
            Ozbush
            Hi ozbush,

            Makes sense on why you want the full blank plate in, my misunderstanding sorry.
            Will be interesting to hear from the guys on the adjustment.
            Can you programme the throttle position to be 100% open? Other than shutdown.

            ####.

            Comment


            • #36
              Originally posted by Anth120playdo View Post
              Hi ozbush,

              Makes sense on why you want the full blank plate in, my misunderstanding sorry.
              Will be interesting to hear from the guys on the adjustment.
              Can you programme the throttle position to be 100% open? Other than shutdown.

              ####.
              Well the current and existing EGR system has to be in perfect condition to work with our Mapper.

              To explain briefly how EGR system works,
              When the car is not accelerating and in cruise, car computer will command EGR valve to open by modulating the EGR valve solenoid then reads the EGR valve position by using its position sensor.
              Then it reads the MAF value and check to see if it lost 15% of air flow due to EGR valve is open and exhaust gas is now flowing into inlet manifold which means it introduced deliberate leak of inlet manifold pressure and of course MAF sensor value will drop due to leak coming from exhaust port.
              If the predetermined MAF drop value is not met then car computer will adjust EGR valve position until it reaches the value. If it could not get the expected value then it will try many tricks to see if it gets the value again by shaking or vibrating the EGR valve. If it still can't get the value then it will record first failure then try again and again.

              But then driver might accelerates again then the whole failure count will be lost. And the whole EGR system starts again.
              In counting failure, when it reaches fail count say 256 times then it will record first EGR failure and MIL will be turned on.
              Of course the nature of the failure will be recorded together such as P0401 insufficient EGR gas flow detected or maybe P0402 EGR gas flow excessive detected and so on.

              The expected MAF drop value is different according to RPM, ie at idle 15%, 1500rpm 21%, 2500 rpm 32%, 3500 rpm 38% and so on.
              The mapper will have to match these values by artificially dropping the MAF value to fool the car computer as if all is working despite EGR gas pipe is fully blocked by blanking plate.
              Of course there are more EGR function, such as EGR diagnostic, I can't describe everything here but I'm explaining to understand how it works by describing an example.

              So the EGR system has to work perfectly to work with mapper.
              As long as EGR system is reasonably functions then mapper will work absolutely reliably too. Because both are computer system and it will dance together until engine is turned off.

              There were many car computer systems for many cars in the world but nowadays it seems only Bosch and Nippon Denso are dominating the market. However, Almost all of those things such as car computer (ECU, PCM whatever they called), sensors and injectors are all originated from Bosch.

              Nippon Denso sensors and injectors are all from Bosch initially from 1970-80s produced under the license from Bosch and now they got their own system but I suspect they still pays royalties to Bosch.
              So when I see the car computers they are all the same either Bosch or Nippon Denso makes no difference, they are identical.

              Ozbush.

              Comment


              • #37
                Hi Ozbush,
                Read all your posts with fascination, wish I had the understanding but it takes all sorts I suppose,
                I have the 1KZ - TE engine in my 06 Prado are you doing anything for this motor , this is the only sight I look at and everyday there is something new to read, consequently still procrastinating on upgrading engine ,I do have a 3inch exhaust and that's it , , but still considering a chip for better towing my caravan , been intouch with GTURBO here in Perth who seem to have a good understanding of various upgrades to my vehicle without baffelling me.so any info would be most appreciated by 1KZ owners I'm sure,
                Cheers Alan.

                Comment


                • #38
                  Originally posted by Dabeanian View Post
                  Hi Ozbush,
                  Read all your posts with fascination, wish I had the understanding but it takes all sorts I suppose,
                  I have the 1KZ - TE engine in my 06 Prado are you doing anything for this motor , this is the only sight I look at and everyday there is something new to read, consequently still procrastinating on upgrading engine ,I do have a 3inch exhaust and that's it , , but still considering a chip for better towing my caravan , been intouch with GTURBO here in Perth who seem to have a good understanding of various upgrades to my vehicle without baffelling me.so any info would be most appreciated by 1KZ owners I'm sure,
                  Cheers Alan.
                  Hi Dabeanian,
                  I am not sure about 1KZ diesels.
                  I will have a go at it when I get over with 1KD engines.
                  In the mean time, is it possible for you to take some photo around air cleaner box where Mass Air Flow sensor might be?
                  And then post it here so I can have a look at it.
                  It's got to have intake air flow meter to know how much air is coming for turbo charger.
                  I can see it has EGR system built in but I couldn't find MAF sensor.
                  Do you have any info? Or anyone?
                  If it has a MAF sensor then the implementing our Mapper is very easy.

                  I call my device Manual Mapper. It means you can alter fuel delivery to diesel engine to control the power.
                  Instead of directly tempering the ECU or injector circuit to control the fuel delivery. Instead, I control air flow value to the computer so I can control fuel delivery indirectly with manual dial. It is a same thing and a lot safer and of course a lot cheaper way to control fuel delivery.

                  Please let me know if you got anymore info about your engine.

                  Ozbush

                  Comment


                  • #39
                    i have mine installed ( still waiting on the other full plate to arrive)
                    i had a quick drive yesterday into town and back with a trailer on and on -8 and all drive nice no loss in power
                    instant km/L seems to be better

                    will test it with the camper tomorrow with a longer run to Moonta
                    2008 Dune D4D manual GXL update - with lots of fruit !! + Roma Razorback Off Road Van

                    Comment


                    • #40
                      Hi Ozbush,

                      Does your device connect to both the MAF and the EGR valve?

                      Cheers
                      Leigh
                      HKB Electronics, manufacturer of the Alternator Voltage Booster, Silver 2008 D4D,Lifted,Underbody protection, Alternator Voltage Booster, Tiger Z winch, Lightforce DL, Air Horns, Tanami Drawers, Drop down fridge slide, Outback cargo barriers, Rotronics dual Battery system, Polaris GPS, HF/UHF/VHF, Radio speaker combiner, Long ranger water tank, Diff breathers, Inverter, Snorkel and others

                      Comment


                      • #41
                        Originally posted by Razorback81 View Post
                        i have mine installed ( still waiting on the other full plate to arrive)
                        i had a quick drive yesterday into town and back with a trailer on and on -8 and all drive nice no loss in power
                        instant km/L seems to be better

                        will test it with the camper tomorrow with a longer run to Moonta
                        Hi
                        Try +10% for more power. You will love it.
                        Some people saw a bit of black smoke when they set on +15%, so I wouldn't recommend it.
                        And also in some rare cases setting -15% caused error code so I wouldn't recommend it either, but try to see if you want test.

                        The most popular setting for the mapper was always minus 5 to 8% for economy and +5 to +10% for more power.

                        There is a lot of difference between -10% and +10%. Some sensitive people can feel that by feel of the pants.
                        I am wondering if you can try both and see how you feel.

                        Thanks for everything

                        Ozbush

                        Comment


                        • #42
                          Originally posted by LeighW View Post
                          Hi Ozbush,

                          Does your device connect to both the MAF and the EGR valve?

                          Cheers
                          Leigh
                          Yes Main body of the mapper connects to MAF sensor connector and one wire need to be fetched from EGR position sensor.

                          Comment


                          • #43
                            Just to clear the cobwebs, I thought the MAF was only used in a diesel engine
                            for EGR control, how does your device modulate the fuel flow using just the
                            MAF and the EGR?
                            HKB Electronics, manufacturer of the Alternator Voltage Booster, Silver 2008 D4D,Lifted,Underbody protection, Alternator Voltage Booster, Tiger Z winch, Lightforce DL, Air Horns, Tanami Drawers, Drop down fridge slide, Outback cargo barriers, Rotronics dual Battery system, Polaris GPS, HF/UHF/VHF, Radio speaker combiner, Long ranger water tank, Diff breathers, Inverter, Snorkel and others

                            Comment


                            • #44
                              Originally posted by LeighW View Post
                              Just to clear the cobwebs, I thought the MAF was only used in a diesel engine
                              for EGR control, how does your device modulate the fuel flow using just the
                              MAF and the EGR?
                              Hi Leigh,
                              Yes the MAF sensor is used for EGR gas metering, but also it is still the part of whole air flow sensing mechanism.
                              However, the last and final authority is hold by MAP or turbo boost sensor conjunction with MAP IAT.
                              In other words, final fuel injection amount is decided ultimately by boost pressure and the boosted air temperature.
                              But you can still influence fuel delivery by altering MAF value in minute amount, that is what I am using to control.
                              The EGR system is always trying to achieve overall air quantity balance by adjusting EGR valve position to regain overall air value.
                              Fore example, if normal air flow was 100g/sec at MAF and EGR leak amount is say 20g/sec, then when the EGR is activated car computer will expect to see the value of 80g/sec at MAF then car computer knows all is ok the overal value of incoming air is still 100g/sec (including 20g of dirty gas).
                              If not then car computer will adjust EGR valve until they get 80g/sec at MAF which they achieves overall gas flow of 100g.
                              So it is leak valve control technology:-).

                              I hope this is enough explanation for you, otherwise it is gonna be all night session with a box of beer.

                              Cheers

                              Ozbush

                              Comment


                              • #45
                                So your basically telling the ECU there is more "clean" airflowing through the system
                                so it can add more fuel?
                                HKB Electronics, manufacturer of the Alternator Voltage Booster, Silver 2008 D4D,Lifted,Underbody protection, Alternator Voltage Booster, Tiger Z winch, Lightforce DL, Air Horns, Tanami Drawers, Drop down fridge slide, Outback cargo barriers, Rotronics dual Battery system, Polaris GPS, HF/UHF/VHF, Radio speaker combiner, Long ranger water tank, Diff breathers, Inverter, Snorkel and others

                                Comment

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