blocking off the EGR on a zd3lt

Sorry to hear about your engine Carl.

I hope you are not going to buy a ticket in the same (ZD30) lottery !!!!!
Colin.

oops sorry Mike
pays to be sober when replying

No wurries Col I came very close to following in your footsteps and built my own Toni
Mike

Bentaxle,

A Dawes valve is US$45 delivered to AU. I’ve fitted many with excellent results. It’s not a specialist job, all you need is a boost gauge to set it up.

Good quality needle valves are available from Dependable Distributors in Adelaide for $60 to complete the manual controller. It doesn’t dump overboost, but stops the turbo from producing it.

Dawes Valves available from 3barracing in the USA
http://www.3barracing.com/product_8.htm

Dependable Distributors http://www.dependabledistributors.com/ phone: (08) 8340 1222 and ask for TDi Needle Valve Kit.

All instructions to do the job HERE

Let me know if you need to know any more. chaz@conody.com

Chaz why would need a manual controller once you set the Dawes valve?

I know how you feel mine let go at 140000 hole in 3 and 4 cost me $10400 then 6 weeks later stripped 5th gear internal spline $1400 can't afford to get rid of it now but must admit it goes well now just get nervous on big trips but what can you do.

Carl,

A Dawes TDi valve works much like a switch to stop boost at the level you set it at, but it can’t control your spool up rate. When you bypass the ECU boost control solenoid, you’ll put full vacuum to the turbo actuator which will cause your spooling to happen very fast and possibly get close to the surge area of the turbo. Turbo surge can destroy a turbo very quickly.

We call it a manual boost controller, but essentially it’s just the combination of a Dawes TDi valve and a small needle valve which we use to bleed off a small amount of vacuum to the turbo actuator, so that your spooling rate is reduced to an acceptable level.

By combining the two valves you can have full control of your turbo under any conditions that aren’t affected by the ECU and it’s strange characteristics. When set up correctly, your VNT turbo will work just like a conventional turbocharger and give you boost every time you use the throttle, not when the ECU decides you need it.

I use two Dawes valves to give me two different maximum boost levels. One is set at 10psi for low speed driving around town and good fuel consumption when I don’t need additional power. The other Dawes TDi valve is set to 15psi for towing, powering up hills and at high speed when my EGT’s start to get up a bit high. The needle valve is dash mounted so that I can vary the boost at any time, but I generally don’t need to do that once it’s set to give a good mid range spool rate.

This system gives me reasonable fuel consumption, all things considered around 12L/100k’s and I have 127hp at the rear wheels. I have gained power and my boost never exceeds 15psi, so the negine is under less stress and runs much cooler EGT’s as a result. Apart from replacing the turbo for a waste gate turbo like the Navara uses, this must be the best way to overcome the ZD30 Patrols inferior boost control system considering it can be done for just over $100.