EGR & FCV

mackruss · **Posted:** Fri Sep 05, 2008 8:55 am

Well as a newbie and with much research done with regards to the options available for the EGR and FCV mod on this and other forums, this is what i eventually did.

Disconnected the battery and removed, moved the fuel head and lunged at the EGR. Loosened the two bolts and looked for the spring that was supposed to be holding the EGR
to the block and then realised that there is no spring i must just spring it back a bit. Did this and made a blocking plate to fit in out of stainless with a little lug on it to hold with a pliers.
Didn't need to use the lug anyway it's there now. Fastened the two bolts and then decided to wrench the connector from the EGR that i wasn't able to do previously just for the sake of it. I then
placed it back where it belongs.

I then proceeded to dismantle the FCV as per my understanding and this went off okay removing the butterfly carefully.Inspected the hoses for oil and they were coated thick. The FCV itself was
lined with oil and a thick oily gunge. Cleaned as best as i could do and then i tried to fathom out why i had removed the butterfly from the FCV in the first place. Perhaps someone can explain the reason why because the EGR now has a blocking plate and the FCV is open permanently, for what reason?

Can this oily gunge not be re-routed to a ccv filter contraption that i intend fitting to my EHM soon rather than have it pass through the FCV and clog up everything. I can imagine what the intercooler must look like......

Anyway it was fun and no CEL at last. I look forward to making a oil / vapour filter for the CCV after some input from the forum.

Thanks for all the tips and advice guys.

dgeist · **Posted:** Fri Sep 05, 2008 9:12 am

FVC will still be actuated by the computer when it's "supposed" to be getting recirculated gasses from the EGR. That's one of the really nice things about the SEGR. When the vehicle is in anything but P/N, the FCV is left wide open. BTW, it's an unwritten rule that you have to post pictures when you do something neat (like fabricate a blanking plate), so post some please

As for your sludge, the EHM will take care of new oil, so at least you've triaged it. Lots of folks have plumbed in "Mann Provent" filters (made for bigger diesel engines originally), and many have also made home-brewed filters (brillo pads in PVC pipe, pneumatic tool air filters, etc).

Dan

mackruss · **Posted:** Fri Sep 05, 2008 9:25 am

Without the butterfly my FCV is permanently open and the only noticeable change is during shut down when i get a kick in my pants
from the last stroke. I can live with this considering the long term positive effects of the mod and no intricate wiring which i'm not sure
i would have had the patience to do considering the fact that i wanted to beat the hell out of the EGR when i saw it close up.

Russ.

MTB_TDI · **Posted:** Fri Sep 05, 2008 5:52 pm

Mackruss,
Glad to see you got it done. I have pics of how I did it, as you know. I can post them later if anyone wants to see them. My CRD shuts down similar to a cummings. It makes me smile everytime I start it up and don't see a CEL!!! Easy way to do it!!!

Larry R. · **Joined:** Sun Jan 21, 2007 1:35 am **Posts:** 92

I'd be interested in seeing the pics MTB_TDI.

mackruss · **Posted:** Sat Sep 06, 2008 4:41 am

MTB & MACKJ

Thanks once again for the pics and useful info with the EGR mod, makes it so much easier when you can see what needs to done before hand.

Now, what is this mod called, can't say SEGR surely, no module installed how about BPEGR for blocking plate?

MACKR.

MTB_TDI · **Posted:** Sat Sep 06, 2008 12:47 pm

Larry R. wrote:

I'd be interested in seeing the pics MTB_TDI.

I'll post when I get home on Monday. Hopefully anyway.

CATCRD · **Posted:** Sat Sep 06, 2008 1:37 pm

mackruss wrote:

Well as a newbie and with much research done with regards to the options available for the EGR and FCV mod on this and other forums, this is what i eventually did.

Disconnected the battery and removed, moved the fuel head and lunged at the EGR. Loosened the two bolts and looked for the spring that was supposed to be holding the EGR
to the block and then realised that there is no spring i must just spring it back a bit. Did this and made a blocking plate to fit in out of stainless with a little lug on it to hold with a pliers.
Didn't need to use the lug anyway it's there now. Fastened the two bolts and then decided to wrench the connector from the EGR that i wasn't able to do previously just for the sake of it. I then
placed it back where it belongs.

I then proceeded to dismantle the FCV as per my understanding and this went off okay removing the butterfly carefully.Inspected the hoses for oil and they were coated thick. The FCV itself was
lined with oil and a thick oily gunge. Cleaned as best as i could do and then i tried to fathom out why i had removed the butterfly from the FCV in the first place. Perhaps someone can explain the reason why because the EGR now has a blocking plate and the FCV is open permanently, for what reason?

Can this oily gunge not be re-routed to a ccv filter contraption that i intend fitting to my EHM soon rather than have it pass through the FCV and clog up everything. I can imagine what the intercooler must look like......

Anyway it was fun and no CEL at last. I look forward to making a oil / vapour filter for the CCV after some input from the forum.

Thanks for all the tips and advice guys.

So you have a blocking plate installed in front of the EGR valve, and the throttle plate removed from the FCV? Any check engine light? How much have you driven it like that? Do you mean you plugged the EGR valve connector back in, or left it unplugged?

mackruss · **Posted:** Sat Sep 06, 2008 1:52 pm

That's right, did it on Friday, so far so good and no CEL. Gives a bit of a kick at shut down without the butterfly in the FCV which is minor.

MTB_TDI · **Posted:** Sat Sep 06, 2008 2:06 pm

CATCRD wrote:

So you have a blocking plate installed in front of the EGR valve, and the throttle plate removed from the FCV? Any check engine light? How much have you driven it like that? Do you mean you plugged the EGR valve connector back in, or left it unplugged?

Yes the blocking plate is in front of the egr valve, so no exhaust will get into the egr valve at all. I used a piece of HVAC sheet metal cut into a 1.5" x 1.5" piece. I left a tab on it like MackJ and then pulled the FCV and removed the butterfly valve. I have over 900 miles on the mod and no CEL. The only noticeable differnce is that it is a little rougher on shut down. The nice thing about this is that you can reverse it very easily and it is pretty easy. I started out by putting the blocking plate in from below. It is much easier to do by moving the FMH off to the side and then the egr pipe is easily accessed.

Can you see the pics? This is the first time I have posted pics on here.

Larry R. · **Joined:** Sun Jan 21, 2007 1:35 am **Posts:** 92

Have you seen any change's in milage with this set-up?

MTB_TDI · **Posted:** Sat Sep 06, 2008 4:25 pm

I got 26.5 MPG on my trip to CA at 75mph. that is 75 mph indicated on GPS or 78 on the speedo. That is the best I have ever got. My jeep only has 21K miles on it right now. It should pick up later. I have run the jeep with the maf unplugged for quite a while too. This is very simple to do, and if you don't like it, change it back

CATCRD · **Posted:** Sat Sep 06, 2008 11:37 pm

mackruss wrote:

That's right, did it on Friday, so far so good and no CEL. Gives a bit of a kick at shut down without the butterfly in the FCV which is minor.

Well hell's bells! If I can deal with a rougher shutdown, why would I wire in an SEGR? Keep us updated if any CEL comes on.

MTB_TDI · **Posted:** Sun Sep 07, 2008 12:39 am

Some people want to be able to switch it back to a functioning EGR a little easier, like via a switch. That way they can go get emissions tested really easily. I don't have to worry about that. I will be headed back to Vegas tomorrow and then back to Utah on Monday. I'll let you know if I get a CEL. I turned my EGR off this way because I really didn't want to cut the wires on my jeep and it would take longer to do also.

mackruss · **Posted:** Sun Sep 07, 2008 3:43 am

MACKJ did this awhile ago down under and said at the time that there was no CEL.

Did mine on Friday, Sunday now and still none.

fastRob · **Posted:** Sun Sep 07, 2008 7:11 am

Is it correct to assume that both the EGR has to be blocked off and the FCV butterfly must be removed?
Or CEL lights up?
FCV, any secret location or where is the rascal??
The SEGR kit scares me.
Any chance of not being able to shut er down?

ATXKJ · **Posted:** Sun Sep 07, 2008 8:33 am

I don't know about the CEL - but the FCV is a performance killer

i.e. the FCV is a new idea - it's not on older diesel engines - it exists to choke the air flow on the intake to cause a 'vacuum' on a pressurized intake - that allows atm pressure exhaust to be pulled into a pressurized intake line. The only positive is that they also close it down on engine shutdown to make a smoother shutdown.

necessary? not really, the older diesels don't have them - now there were a couple of horror stories form diesel mechanics of runaway diesel engines - i.e. a bad seal somewhere and the engine was pulling in oil which continued to run even after the fuel was shutdown - the FCV would prevent that -but I don't think that was ever common the folks mentioning it had years of maintenance experience (and I think it was targeted at some specific bus engines)

but because of the comments the SEGR was intentionally set to allow the FCV to function on shutdown - it was fairly easy to design in. (well easy for me - I wasn't doing it)

however there are lots of diesel engines that don't have FCV , and the only comment anyone ever had about runaway engines - traced back to floor mats sliding into the pedals.

Larry R. · **Joined:** Sun Jan 21, 2007 1:35 am **Posts:** 92

I think that the flow control valve is usefull on down-hill desecents, it seams to act like an exhaust brake when your cruise is set.

Goglio704 · **Posted:** Sun Sep 07, 2008 11:51 am

The transmission will downshift to help keep the speed down, but the FCV isn't supposed to shut.

MTB_TDI · **Posted:** Mon Sep 08, 2008 8:44 pm

I put another 750 miles on the CRD and no CEL.

From my understanding, if you don't pull the butterfly, the computer will sense that there is less gas (air and exhaust) dumped into the engine if the EGR is blocked. The butterfly will control fresh air coming into the engine by closing partially to reduce the volume of air when the EGR opens, hence it sees no deviation in "airflow." If you block the EGR and then pull the butterfly, the engine still gets what it is supposed to get but doesn't see any deviation so no CEL. Others may correct me if I am wrong. I may not be 100% clear either.

EGR & FCV

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