Outer Limits 4x4 Board

HI,

I have a 2003 td42 IC turbo diesel, which is blowing a bit too much smoke and the diesel specialist thinks the egr might be stuck open.

I much rather tinker with things myself and learn the truck as I go, than send it off to a mechanics.

Some people say block it off, others say dont, but most of the info ive found has been about the grenades.

What can people tell me about the egr on the patrols, how to clean it and check its function.

is it worth blocking it off?

cheers
Ben

block it off. complete instructions on patrol4x4. only thing i can't remember if they use the intake butterfly for egr or not.

I wouldn't think that the egr valve would make it chuff like you describe. More like a clogged air filter or fuel screw wound up too far.

EGR is most workshops excuse for I DON'T KNOW. Probably just wanted you to book it in so he could ring you with some lame excuse that would end up costing you more.

Fuel screw x2

Most issues from the EGR are related to the condensate forming a sludge inside the factory intercooler, reducing its ability to cool the intake charge. I vote block it off, and while you're at it, pull the intercooler off and run some brake cleaner or carby cleaner through it to remove any existing sludge.

I think this might help?

This is how I removed (not blocked) the EGR on my '93 GQ TD42. There's pictures on that link as well...
http://www.patrol4x4.com/forum/showthread.php?t=55897" onclick="window.open(this.href);return false;

Cheers
Mr. D

Abitibi wrote:I think this might help?

This is how I removed (not blocked) the EGR on my '93 GQ TD42. There's pictures on that link as well...
http://www.patrol4x4.com/forum/showthread.php?t=55897" onclick="window.open(this.href);return false;

Cheers
Mr. D

I was thinking, 1993? EGR?
Then I saw Canada.

thehanko wrote:HI,

I have a 2003 td42 IC turbo diesel, which is blowing a bit too much smoke and the diesel specialist thinks the egr might be stuck open.

I much rather tinker with things myself and learn the truck as I go, than send it off to a mechanics.

Some people say block it off, others say dont, but most of the info ive found has been about the grenades.

What can people tell me about the egr on the patrols, how to clean it and check its function.

is it worth blocking it off?

cheers
Ben

That TD42 is a bit of a lemon, just sell it to me cheap, cut your losses, grab one of the new ZD30s (They have fixed the problems)

Seriously, black smoke, is fuel. Fuel or not enough air.
Restricted intercooler or air intake could cause this.
Too much fuel could cause.
In some circumstances the EGR "could" have been a catalyst. But it wont fix the problem.

I reckon Coxy 321 is on the money.

thelux wrote:EGR is most workshops excuse for I DON'T KNOW. Probably just wanted you to book it in so he could ring you with some lame excuse that would end up costing you more.

Fuel screw x2

I trust his advice as he was recommending i check the egr as first option then if thats not it come to him, he was suggesting i take my business elsewhere as he specialised more on the injection side of things.

Anyway he looked at it pointed out that the injectors had already been worked on and with its low k's would doubt them to be the problem.

I have a pyro pre turbo and im not getting hot at all. so doesnt point to a heavy fuel screw???


Some more info is that its running modified turbo intake and exhaust, about 17psi etc etc but all this was done before my time.

I will definitely rip off the intercooler and check it out.

HIs reasoning behind the egr was that if its stuck open then exhaust is being put into the intake reducing the amount of fresh air = richer mixture effectively = smoke.

it tends to blow smoke accelerating from idle etc when you not going to have high egts etc rather than at crusiing revs when the egr would normally be opening anyway? but im not 100% on any of this.

thanks for all the advice, keep it comming.

bj on roids wrote:

thehanko wrote:HI,

I have a 2003 td42 IC turbo diesel, which is blowing a bit too much smoke and the diesel specialist thinks the egr might be stuck open.

I much rather tinker with things myself and learn the truck as I go, than send it off to a mechanics.

Some people say block it off, others say dont, but most of the info ive found has been about the grenades.

What can people tell me about the egr on the patrols, how to clean it and check its function.

is it worth blocking it off?

cheers
Ben

That TD42 is a bit of a lemon, just sell it to me cheap, cut your losses, grab one of the new ZD30s (They have fixed the problems)

Seriously, black smoke, is fuel. Fuel or not enough air.
Restricted intercooler or air intake could cause this.
Too much fuel could cause.
In some circumstances the EGR "could" have been a catalyst. But it wont fix the problem.

I reckon Coxy 321 is on the money.

Time to cut my losses i know - how does a fiver sound

Is it really black sooty smoke or is it a little grey but almost black?

thelux wrote:Is it really black sooty smoke or is it a little grey but almost black?

bit hard to tell, I would say black - the back of the tray is definitely black now, but it could be a bit gray, you never see it that clearly due to the coloured background or road etc.

the difference would mean?

thehanko wrote:

thelux wrote:Is it really black sooty smoke or is it a little grey but almost black?

bit hard to tell, I would say black - the back of the tray is definitely black now, but it could be a bit gray, you never see it that clearly due to the coloured background or road etc.

the difference would mean?

If you're getting soot on the back of your car - then its fuel (as in overfuelling). Maybe start to turn it down a bit, going 1/8 to 1/16 of a turn at a time until you're happy with the smoke/power ratio.

If it's a little bit grey it's burning oil as well which could make it look alot more smokey than it actually is.
How much work has your motor done?

With Diesels it's a bit hard to tell, however most will puff a bit of whitish grey smoke on startup (this is unburnt fuel).

If it blows a f$#@ load of white smoke the timing could be out.

However if its just black it is overfueling (can be adjusted with the mixture screw on the IP)

If it's a little greyish it's burning oil as well this can be Stem Seals (quite an easy job if you have the right tools) or rings depending on the amount of work your engine has done.

Also if its blowing smoke a bit whitish that could also be fuelling up but it would miss and blow heaps of smoke if this was the case (generally caused by an air leak in a fuel line or injector)

thelux wrote:If it's a little bit grey it's burning oil as well which could make it look alot more smokey than it actually is.
How much work has your motor done?

only 120 thousand k's, doesnt look like oil type smoke.

its only started getting worse in the last few months to the stage it stains the back of the tray - so something has changed like a bad injector or stuck butterfly or what ever.

if it was blowing soot then got smoky making it look worse that wouldnt explain the extra soot on the back of the car - it used to stay white.

i highly doubt it buring oil at all.

thanks though.

Edit above post^

My old Land Cruiser had timing out and used to blow very fuelly white smoke and still used to soot up the back door. Looks can be deceiving.

the other thing he suggested before I start getting him to look at injectors etc was tappets????

I know nothing of these, what they do etc etc and will likely get someone professional to look at them - again he was sending me elsewhere to get them checked. any thoughts on those? and how they would effect the truck?

thehanko wrote:the other thing he suggested before I start getting him to look at injectors etc was tappets????

I know nothing of these, what they do etc etc and will likely get someone professional to look at them - again he was sending me elsewhere to get them checked. any thoughts on those? and how they would effect the truck?

Maybe if they are too tight and holding the valve slightly open, or too loose and not opening the valve enough.

Is it very 'ticky'?

thelux wrote:

thehanko wrote:the other thing he suggested before I start getting him to look at injectors etc was tappets????

I know nothing of these, what they do etc etc and will likely get someone professional to look at them - again he was sending me elsewhere to get them checked. any thoughts on those? and how they would effect the truck?

Maybe if they are too tight and holding the valve slightly open, or too loose and not opening the valve enough.

Is it very 'ticky'?

ticky when cold, yeah but not when hot.


I pulled what i assume was the egr valve out today. ill post pics in a bit.

sooty as hell, and sludgy where it continued into the intake. but as far as i could tell it was working fine, it definitely wasnt stuck open.

To get to it i pulled the IC off and checked it out too. clean as a whistle, maybe 1/2 a teaspoon of oil in one end of it, probably from the breather hose, so little that it hadnt coated the inside of the ic at all.

It blows alot of smoke when i start off the line at the lights, almost like the compensator is too heavy pre boost, but i was told these setting dont tend to go out of whack.

The only reason I havent thought it was simply over fueling is the low egt's and that when i first got it it wasnt getting sooty at all.

bit stumped where to go next. happy to spend coin on it but which way to toss the dollars first?

Doesnt seem to be making as much power as i would have thought a troll running 17psi and overfueling would make - dont get me wrong its not bad but i thought it would pull more if it was wound up too much.

maybe im not remembering my last patrol acurately lol.

I might wind the fuel back and see what happens, at least it is reversable and if it doesnt make a difference then i need to look at injectors etc.

so this is the egr???? if not i tried blocking off something else lol.



wiped the soot off but it was moving freely anyway.



This is how clean the IC is.

Well it must be working if it moves freely and is not gunked up with crap.

What is your EGT sitting at under full load?

550 pre turbo uphill towing a load. whic is what i would expect if the thermometer was in the dump rather than the manifold.

Did you get this sorted? Sorry I haven't been on in months, have been lacking internet lol.

Not really, lol.

I was about to book it into berrima diesel service for some love but they wanted $1500

So the next plan was to pull the injectors and have them tested but havent had time.

failing that i was going to knock the fuel back a touch.

It has also been suggested that advanced fuel timing can lead to more soot but is often done when tuning the td42.