Tuesday, Jul 28, 2015 at 12:24
Broodie, blocking the EGR system will usually lead to a CEL (
check engine light) appearing on all modern systems.
It is usually a P0401 insufficient EGR flow.
You can generally overcome this by having a small hole in the blanking plate (usually 10mm - 12mm or so), or I have seen this done in the EGR butterfly plate itself with operational vacuum line disconnection, and although this seems to defeat the purpose a little, it does stop a large % of particles being put through the intake system.
Other things you can do to eliminate CEL is an ECU tune, expensive but you can get other tuning benefits too, or on some vehicles you might be able to keep the EGR closed with vacuum line disconnections.
The CEL is the big issue, need to keep this off to enable other (possibly genuine) warnings to be picked up.
The PJ / PK
Ranger and BT50 equivalent has a new experimental mapper that keeps the EGR closed, and no CEL, also can adjust fuel up / down a little for power of econ when needed.
See thread here
Manual mapper
This also allows for full blanking plate and the dreaded EGR cooler to be blocked off, as these are notorious for failures anytime from around the 100k mark.
Hopefully once trials are done, the maker will work on other makes and models, as this is a far better unit than some coming out of the US (at the moment for Mits Triton / Pajero) that aren't quite as safe with their cheap fix (5c - 10c resistor to trick ECU into thinking it's below 5c or whatever temp the EGR stays shut at).
You can also fit an oil catch can, which won't stop the EGR particulates recycling, but does stop the oily mist recycling to the intake.
When the oil mist is mixed with the particulates, this is where you can get the MAP sensor all caked up, and eventually the intake manifold is severely restricted with the black tar like gunk, sometimes blocking up nearly completely !
I have had a Provent 200 style can form about 50k, now 100k, and my intake manifold is pretty clean.
MAP cleans since just show the dusty black soot from the EGR, but now with the mapper mentioned above, I hope to both get better performance / fuel econ, and less soot in the system too, which can lead to engine oil going black sooner.
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