EGR Disconnect Instructions
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Former Vendor
Joined: Mar 2004
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From: Hendersonville, NC
Originally Posted by FredsF250TD
Don't have much time but one more thing to think about, the PCV gasses. These, mixed with the exhaust gasses from the EGR is what causes the mess in the TDI's intakes. What about venting the PCV gasses into a catch can instead of into the intake? I'm assuming our motors vent crankcase gasses into the intakes?
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From: stoneboro, pa
Originally Posted by PSD 60L Fx4
I bet there is a way to vent BOTH of them outside the vehicle. Im not sure about the EGR as there is not really a way to splice the system, however it is a good idea. This way, no codes would be thrown at all.
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From: Central Texas
Originally Posted by PSD 60L Fx4
Any check engine light? If you get a chance, pull the codes and see if you got the same two that I did. I think if we all get to work on this, we can totally kill the codes.
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Former Vendor
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From: Hendersonville, NC
Originally Posted by FredsF250TD
Don't have much time but one more thing to think about, the PCV gasses. These, mixed with the exhaust gasses from the EGR is what causes the mess in the TDI's intakes. What about venting the PCV gasses into a catch can instead of into the intake? I'm assuming our motors vent crankcase gasses into the intakes?
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From: Stockbridge
The SES light should only come on with the CA emissions equipped vehicles. The way some get around this is to hook up another EGR valve, big$. You can get a failed one from the dealer if you know a tech. Install the failed one on the engine, (make sure its failed closed) hook up your good EGR to the connector, no codes, no lights. Theres another reason for going this route. The EGR works in conjunction with the VGT actuator, with the EGR disconnected people have reported about a 1 psi loss of boost at WOT. When the ECM detects the EGR is not functioning properly (it does have a feedback loop) it must go into some sort of limp mode, limiting boost at WOT. Ive heard a couple of people report this, they have decided to just hook it back up.
As far as the VW TDI. My son and I cleaned his Golf TDI intake a few months back. The intake where the EGR gasses enter is about 2.5", it was so coked up there was about a 3/4" hole remaining!
I couldn't believe it was still running let alone getting 45mpg. It had 80K miles on it at the time.
As far as the VW TDI. My son and I cleaned his Golf TDI intake a few months back. The intake where the EGR gasses enter is about 2.5", it was so coked up there was about a 3/4" hole remaining!
I couldn't believe it was still running let alone getting 45mpg. It had 80K miles on it at the time.
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From: Stockbridge
Originally Posted by PSD 60L Fx4
Ive been searching the 6.0 Bible over, and I just cant find anything on the PCV...anyone know where its located?
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From: Stockbridge
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Former Vendor
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From: Hendersonville, NC
Originally Posted by psdwanabe
I found the system. Look here.
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Former Vendor
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From: Hendersonville, NC
Originally Posted by psdwanabe
The SES light should only come on with the CA emissions equipped vehicles. The way some get around this is to hook up another EGR valve, big$. You can get a failed one from the dealer if you know a tech. Install the failed one on the engine, (make sure its failed closed) hook up your good EGR to the connector, no codes, no lights. Theres another reason for going this route. The EGR works in conjunction with the VGT actuator, with the EGR disconnected people have reported about a 1 psi loss of boost at WOT. When the ECM detects the EGR is not functioning properly (it does have a feedback loop) it must go into some sort of limp mode, limiting boost at WOT. Ive heard a couple of people report this, they have decided to just hook it back up.
As far as the VW TDI. My son and I cleaned his Golf TDI intake a few months back. The intake where the EGR gasses enter is about 2.5", it was so coked up there was about a 3/4" hole remaining! I couldn't believe it was still running let alone getting 45mpg. It had 80K miles on it at the time.
As far as the VW TDI. My son and I cleaned his Golf TDI intake a few months back. The intake where the EGR gasses enter is about 2.5", it was so coked up there was about a 3/4" hole remaining!
I couldn't believe it was still running let alone getting 45mpg. It had 80K miles on it at the time.When one of you guys (with a boost gauge) gets a chance, unhook the EGR and compare it to your hooked-up boost. Let us know if there is any difference between the two. I will try it myself as soon as i get my truck back and pick up some gauges.
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Former Vendor
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From: Hendersonville, NC
I have been trying to determine exactly what kind of valve the EGR valve is; solenoid, ect. I am going to order an EGR puller tool from ford when i return to the dealer to pick up my truck. If it is a mechanical type valve, the valve could probably be "chopped" where as the mechanism still triggers but the valve does not actually open.
As for the PCV, Im still trying to do some more research on it, when i get a little spare time.
As for the PCV, Im still trying to do some more research on it, when i get a little spare time.
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Former Vendor
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From: Hendersonville, NC
Well, since this thread has about died...
Everyone that has disconnected their EGR please post your mileage (total, then miles with EGR unhooked) and the effect it seems to have on your vehicle
Everyone that has disconnected their EGR please post your mileage (total, then miles with EGR unhooked) and the effect it seems to have on your vehicle
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From: 3rd Rock
This will take time now, it has peaked and will settle down then .................start to get more responses over time. Threads actually have a reactively predictable life….
It is a great thread!
It is a great thread!
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Joined: Jan 2004
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From: Nashville, TN
Accumulated Miles: 18,458
Miles with EGR unplugged: 4,764
Effect: Maybe a little quieter. Maybe a slight increase in MPG, but that could be ongoing break-in mileage improvements. My reason to disconnect is HOPEFULLY to not have a gunked up manifold like VW TDI's get.
Since no one has come up with a good reason to remove throttle plate except an opinion about a non-technical, undocumented performance change: "This is simply an obstruction to airflow, and is useless when the EGR is disconnected", I would think that if Ford finds a throttle plate removed and the EGR unplugged that they would have another case to wash hands where they choose for warranty, but if the wire to the EGR was easily replugged and everything else was intact they wouldn't have much to go on. Your truck, your investment, your call.
Miles with EGR unplugged: 4,764
Effect: Maybe a little quieter. Maybe a slight increase in MPG, but that could be ongoing break-in mileage improvements. My reason to disconnect is HOPEFULLY to not have a gunked up manifold like VW TDI's get.
Since no one has come up with a good reason to remove throttle plate except an opinion about a non-technical, undocumented performance change: "This is simply an obstruction to airflow, and is useless when the EGR is disconnected", I would think that if Ford finds a throttle plate removed and the EGR unplugged that they would have another case to wash hands where they choose for warranty, but if the wire to the EGR was easily replugged and everything else was intact they wouldn't have much to go on. Your truck, your investment, your call.
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The thread hasn't died !!!
We've just all been driving our EGR'less trucks!
Disconnected it last week and no check engine lights on my 05/03 Ex.
Do have the P403, P404, & P405 EGR and the P603 KAM codes according to the predator... but no negatives noticed with the disconnect...
And maybe it's perception for me since I knew it is disconnected,
but my wife didn't know it and she commented that it seemed like the engine "got quiet again" .... not like when the pilot injection was still there, but it is a perceptual difference
MPG improvement ??? maybe a bit... but I NEVER watch the mpg anyway so I wouldn't be the one to notice any diff.. if it does improve, fine... but no big deal to me
Overall - worth the 10 seconds or so to disconnect... but I'm not the type to dive into the throttle plate removal either... almost like work to me
We've just all been driving our EGR'less trucks!
Disconnected it last week and no check engine lights on my 05/03 Ex.
Do have the P403, P404, & P405 EGR and the P603 KAM codes according to the predator... but no negatives noticed with the disconnect...
And maybe it's perception for me since I knew it is disconnected,
but my wife didn't know it and she commented that it seemed like the engine "got quiet again" .... not like when the pilot injection was still there, but it is a perceptual difference
MPG improvement ??? maybe a bit... but I NEVER watch the mpg anyway so I wouldn't be the one to notice any diff.. if it does improve, fine... but no big deal to me
Overall - worth the 10 seconds or so to disconnect... but I'm not the type to dive into the throttle plate removal either... almost like work to me
Last edited by jdadamsjr; Jun 28, 2004 at 08:18 AM.