EGR Bypass Tutorial with Turbo Talk

[Killbert]

See the origianal thread at http://www.delicaforum.com/index.php?th ... -videos.7/

This is a HUGE topic in the diesel world. Mainly because in most states performing this modification is ILLEGAL. Well the good news here is that your shiny L300 is emissions exempt so let's just mod away! EGR stand for Exhaust Gas Recirculation. This system takes spent exhaust gasses and reintroduces them into the combustion chamber during cruise in order to cool down the combustion chamber temperatures and improve fuel economy. This system works well... on gasoline engines. I work on a lot of diesel engines and the main culprit of sludge and contamination is the result of the EGR system. This is because diesel emissions are dirty and reintroducing that nastiness just makes things worse. So let's get rid of it.

Step one: Buy your kit! EBAY!!

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Step two: Prepare for removal. Remove driver's side subfloor section (removal of this can be found on another thread)

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Step Three: Locate the enemy. This is the EGR Valve itself. It attaches itself with two 12mm bolts to the intake manifold. It has a metal pipe that connects down to the exhaust manifold with two 12mm nuts. Remove the vacuum line from the EGR Valve and install the supplied vacuum cap to the metal line that originally provided vacuum to the valve. Spray everything with WD40 and wait 30 minutes. Now remove the 12mm bolts up top and the 12mm nuts below. Snake the EGR Valve and pipe out as an assembly. Do not try and remove the pipe from the EGR Valve in the truck; it is unnecessary. Removing the nuts on the manifold may take the thread studs with you. This is because the nut has siezed itself to the stud as a result of heat. I had a spare set of studs laying around; you may not be so lucky.

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Step Four: Install the blockoff plate at the intake manifold and at the exhaust manifold using the supplied hardware. I used a small amount of RTV on the intake manifold to ensure a good seal. A leak here will sacrifice performance and make a mess as it will drip down onto the turbo.

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Here are a few videos that show the whole process and talk about inspecting the turbocharger

https://www.youtube.com/watch?v=e2agIMdkI0I&t=4s
https://www.youtube.com/watch?v=8HPaSpkWD6c&t=8s
https://www.youtube.com/watch?v=AgahbZCwMr4

Kellyn

[Pntyrmvr]

Cooling the cc temps and improving mileage is NOT what and egr system is designed for.

The introduction of exhaust gas into the combustion cycle dilutes the incoming fuel charge resulting in lower temps and fewer NOx emissions. Google it. Diluting any fuel charge results in worse fuel economy as you are introducing an essentially inert compound and thereby reducing the volume available for oxygen and fuel. Google it.

All fuel burning is trying to maximize the temp delta before and after the burn. Exhaust gas introduction limits that delta and therefore efficiency.

"Talk is cheap. Whiskey costs money."

[Killbert]

Cooling the cc temps and improving mileage is NOT what and egr system is designed for.

The introduction of exhaust gas into the combustion cycle dilutes the incoming fuel charge resulting in lower temps and fewer NOx emissions. Google it. Diluting any fuel charge results in worse fuel economy as you are introducing an essentially inert compound and thereby reducing the volume available for oxygen and fuel. Google it.

All fuel burning is trying to maximize the temp delta before and after the burn. Exhaust gas introduction limits that delta and therefore efficiency.

"Talk is cheap. Whiskey costs money."

I know all about Nox. I talk about it in my first of three videos on this topic. Thank you, Sergeant. We're all anxiously awaiting your write up on the subject!

[Morgonzo]

Thanks for the write up Killbert. I've already done mine but if I hadn't this would've help quite a bit I most certainly notice less black smoke and more solid throttle response than when the EGR was on the engine. I will be going back in soon to install an EGT and do the Gallium mod..wish me luck

[Captain America]

Thank you for taking the time to shoot & post the tutorial. Very helpful.

Regards

[Killbert]

No problem guys. Happy to help!