EGR & FCV

journeyjim · **Posted:** Wed Sep 17, 2008 7:30 pm

I tried to block the egr pipe on the side of the engine, put a small piece of gasket material in, and when I started it had a check engine light, put a new map sensor in also, since the old one had, been cleaned with wd 40.
The old one was coated in soot, have map sensor cleaner now.
The egr pipe has a small flange on it, where it meets the block. Didn't find any gasket under the flange?.
Tried turning the key off and on, to clear the light, but it hasn't worked. Checked to make sure that I had plugged everything back in and have.
I have also done the elephant hose before this.
Any body got any ideas, other than take it back apart, and see what I did.

ATXKJ · **Posted:** Wed Sep 17, 2008 8:00 pm

Quote:

Tried turning the key off and on, to clear the light, but it hasn't worked.

Key off/on won't clear it - best way is a code reader, without that you need at least 3 engine cycles-
i.e. start- run to operating temp and then off.

fastRob · **Posted:** Wed Sep 17, 2008 8:06 pm

journeyjim wrote:

I tried to block the egr pipe on the side of the engine, put a small piece of gasket material in, and when I started it had a check engine light, put a new map sensor in also, since the old one had, been cleaned with wd 40.
The old one was coated in soot, have map sensor cleaner now.
The egr pipe has a small flange on it, where it meets the block. Didn't find any gasket under the flange?.
Tried turning the key off and on, to clear the light, but it hasn't worked. Checked to make sure that I had plugged everything back in and have.
I have also done the elephant hose before this.
Any body got any ideas, other than take it back apart, and see what I did.

Did you take out the butterfly on the FCV?
With that valve in place the pressure difference will trigger a CEL.
Did you look at the pictures by MTB_TDI on page one of this thread?

journeyjim · **Posted:** Wed Sep 17, 2008 8:31 pm

I haven't taken the butter fly out of the fcv yet, I wasn't sure on it. But I believe that it's hooked to the intake hose on the same side of the engine?.

MTB_TDI · **Posted:** Wed Sep 17, 2008 9:23 pm

Yes the butterfly is on the same side of the engine as the EGR. You will have to take off the boost hose to get to the FCV. You will likely get a CEL. I have a tune that doesn't give me a CEL when the EGR is blocked off. When I went back to stock, the CEL came on, the only difference was the tuning. I am curious to see if anyone else had tried this and not got a CEL in North America. I know that the Austrailian and the South African ones don't get a CEL.

mackruss · **Posted:** Thu Sep 18, 2008 3:36 am

Yes, still no CEL on mine and that's the South African version.

Looking at the pics on the forum, i can assure you guys that my diesel is identical to the US models but
they may be programmed differently with regards to the EGR operation although i doubt this very much. I'll have to try and find out
about that from the local dealership.

I removed the battery to give me more space and then did the mod. Afterwards i cleared three codes all related to EGR and low flow,
fired her up and no CEL.

I used a piece of steel cut the same shape as the EGR inlet with two holes in it to bolt back on. To get the same shape i pulled the pipe back and slid in a piece of gasket, this left an indentation in the gasket which i used as a template then to shape the piece of steel. I don't know how effective using a piece of gasket will be to block off the flow.

irboogie · **Posted:** Thu Sep 18, 2008 10:48 pm

Well I did the reversal tonight and so far no CEL, I'm going to leave the MAF plugged in for a few days to see if all is well. I did really like the missing butterfly

MTB_TDI · **Posted:** Thu Sep 18, 2008 11:22 pm

irboogie wrote:

Well I did the reversal tonight and so far no CEL, I'm going to leave the MAF plugged in for a few days to see if all is well. I did really like the missing butterfly

Get a hold of Charlie at KermaTDI and ask him how much it would cost to get a tune. Ask for MOD 2. That is the one I am using. Then you can do this mod and not get a CEL!!!! Apparently that is the reason I don't get a CEL. He has figured out how to allow us to block the EGR without getting a CEL.

mackruss · **Posted:** Fri Sep 19, 2008 3:46 am

Or you can buy the SA CRD and not get a CEL :wink:

MTB_TDI · **Posted:** Fri Sep 19, 2008 10:29 am

mackruss wrote:

Or you can buy the SA CRD and not get a CEL :wink:

And get a 6 speed manual!!! That would even be better!!!!

journeyjim · **Posted:** Fri Sep 19, 2008 4:36 pm

Ok, got the butterfly out of the FCV, still have a check engine light. Took it to parts store had them read it, and clear it.
I had p0401 for insufficient egr flow, a p0183 fuel temp, a p0299 turbo under boost. He cleared them, went across town shut it off, and it came back on up on restarting?. These are only short trips to town about 6miles round trip, should I drive a couple of more times, for it to do some cycling?. What was the name of the scan tool, that every one was using to clear codes?. I had the understanding that the egr, couldn't tell if it was blocked off?, or is it that maybe didn't get the plate big enough, and some is going by, used a metal gasket that has an asbestos covering on it for high temps.

ATXKJ · **Posted:** Fri Sep 19, 2008 9:01 pm

Several folks got the Scangauge II - lots of nice features - but you can't leave it plugged in cost ~$150
Harbor Freight has a couple of readers only that are ~$40 -one works - one doesn't I don't know which is which (Sir Sam had a post a while back) so if you try it - keep a receipt and make sure you can exchange it.

Fuel Temp - did you bump the fuel head connection when you were working on the EGR/FCV?
Turbo underboost ?? no idea

journeyjim · **Posted:** Fri Sep 19, 2008 9:30 pm

I don't remember bumping the fuel head, unplugged it and replugged it, going to check to make sure got it plugged in all the way. Trying to burn the tank of fuel that I have in it, loaned it to a customer a few weeks ago, and for letting them use it they filled the tank, it was at three fourths, but they put gas in it, had the tank drained and refilled with diesel, ran it down again to three fourths and refilled it again, going to run it all the way down this time and refill. It didn't have any lights then, so don't know why now.

CRDMiller · **Posted:** Sat Sep 20, 2008 12:04 am

I pulled my butterfly, and plated over my egr, and cleaned out the assembly (oh MY GOD was it full of crap!!! 29k miles worth of non ehm/orm) In the process i stripped out one of the t-15 screws and had to drill it out :P Fun all around

I have it partially re-assembled (wow that bottom flange fitting with the crush clamp/hose clamp is really special) and i want to know if i'll go to jeep hell if i don't replace the gasket on the intake manifold. And should I also replace the crush/hose clamp?

I'm in SoCal and no one stocks parts for the crd, it usually takes 2-3 weeks to get crap via my local stealer. I saw this thread and did not think about the gaskets, and i really want to play with it, so should i wait for a gasket? or just say eff it and slap it back together (with the old gasket)

Thanks for this great idea.

tulsa · **Posted:** Sat Sep 20, 2008 7:56 am

journeyjim wrote:

I don't remember bumping the fuel head, unplugged it and replugged it, going to check to make sure got it plugged in all the way. Trying to burn the tank of fuel that I have in it, loaned it to a customer a few weeks ago, and for letting them use it they filled the tank, it was at three fourths, but they put gas in it, had the tank drained and refilled with diesel, ran it down again to three fourths and refilled it again, going to run it all the way down this time and refill. It didn't have any lights then, so don't know why now.

I think you have done enough. It is OK to run this tank low, but I suggest not to run till empty to avoid damage to the injection pump.
Lewis

CRDMiller · **Posted:** Sat Sep 20, 2008 8:01 pm

So i've done the deed, and i'm getting cel's, yee haw :P

U0121 Lost Communication With Anti-Lock Brake System (ABS) Control Module <-- most likely my reader, although i could have bumped some of the esp/abs stuff
p0401 Insufficient EGR Flow http://www.obd-codes.com/p0401 <-- perhaps because i have an aluminum plate in the way?
p0102 Mass Air Flow (MAF) Circuit Low Input http://www.obd-codes.com/p0102 <-- got me here, this is the first time i've ever had the maf plugged in :P

So it seems you do get a cel when you pull the butterfly and plate over the egr, what gives :P

I was running a cel anyway because of the orm so i'm not crying, though it was a pain in he booty to remove the valve and drill out the butterfly etc, on the upside it was defiantly good to remove the 2-3 handfuls of sh*t i pulled out of the valve/manifold so i call the experience a waRsh

If anyone has any idea's I'd love to hear them. This is a 06 limited with f31/f37

Turbo Tim · **Posted:** Sat Sep 20, 2008 8:17 pm

From page 2 of this thread:

"That is not what I saw on my CRD EGR setup. When I was "Looking" at all the different functions at the same time, I saw that when the EGR was told to open, the MAF reported LESS air going through it immediately. This is because exhaust was now coming in and forcing less air to come in through the turbo. The computer expects to see a reduction in MAF when the EGR is fired off. No reduction = failure = CEL. Also during certain throttle settings, the FCV was also commanded to fire off in conjunction with the EGR forcing even more of a reduction of MAF. Again the computer expects to see this reduction or = failure = CEL.

This is what the SEGR is built around."

This is why we had to build the electronics to fool the computer. If you would have done the SEGR, you wouldn't of had to put a block-off plate in as the wire gets cut to the EGR so it will NEVER open again.
Anyway you can still do the SEGR and know for sure that you will never have any exhaust ever getting back into the engine.

CRDMiller · **Posted:** Sat Sep 20, 2008 9:11 pm

Thanks TTim, that said, it seems there is no way that this is related to my p0102 (maf), right>?

Turbo Tim · **Posted:** Sat Sep 20, 2008 11:10 pm

I don't know what you did, or what your symptoms are. Did you change something?

mackruss · **Posted:** Sun Sep 21, 2008 4:11 am

I would be interested to hear from Turbo Tim why my model is not throwing a CEL after i did the EGR and FCV.

EGR & FCV

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