Thursday, Jul 30, 2015 at 18:22
Yes, terrible design, very prone to failure.
Pretty much engineered to fail !!
You can deal with this a few ways, remembering that the EGR is a legal requirement, but then so is keeping lifts legal and a whole host of other things that are sometimes put aside by owners.
If you block the EGR system, you can then block the EGR cooler hoses (no need to bypass, they are independent of the general cooling system).
You need to block fully to enable a cooler disconnect, and if you do this with the blanking plates available, then you will get a CEL (
check engine light) come on, and this would be a P0401 EGR Flow Insufficient Detected code.
You can get blanking plates with (I think) a 12mm hole . . . this allows enough flow to keep the CEL off, and a good portion of EGR gases out of the intake, but probably not safe to bypass the EGR cooler.
You can turn the CEL off for this code with an ECU tune, $$$ but other tweaks can be done for power / econ and certain things other than that (auto trans point shift for one).
Or, you can get a new experimental module as per the first post below and the second link to more detailed info about the mapper . . .
Is blocking the EGR a worthwhile mod ?Manual mapper project
Besides the particulates being fed back into the intake manifold, there is also oil mist from the PCV system / valve being fed back in there with them, these 2 combined builds up as a black tar like gunk in the manifold, clogging up MAF sensor and eventually restricting flow in the intake system, sometimes clogging it nearly totally !
You can overcome this by eliminating one or the other (particulates or oil mist).
An oil catch can will take most of the oil mist out of the system, I installed one at 50k and my intake is clean apart form black dust form the EGR on the MAP.
The oil mist is also put through the intercooler, which can hold it (there is no drain) and eventually somewhat restrict the cooling action of the unit.
Have heard of people pouring a cup of oil out of their intercoolers.
See some info and other links here . . .
Has anyone fitted an oil catch can ?
I am currently using the experimental mapper, and will be happy if it just keeps the particulates out of my intake system.
Once happy it's reliable, I will use blanking plates on the EGR, and block the EGR cooler inlet / outlet.
AnswerID:
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