How to setup EGR from scratch

ahsanonline (ahsanonline) 2011-05-10 13:04:56 +0500 #1

The engine in question is FIRST gen 5AFE. its the replacement of old 2E carby engine that had no egr (at least i didnt find any way for exhaust gas to get out of the exhaust manifold!)

So i need to set up EGR....i need ideas on how to implement it easily. what stuff will i need?

Xulfiqar (Xulfiqar) 2011-05-10 13:23:12 +0500 #2

WHY in the name of God do you want exhaust gases in your intake manifold?

Flyhigh1 (Flyhigh1) 2011-05-10 13:34:45 +0500 #3

Absurd... Explain plz

ahsanonline (ahsanonline) 2011-05-10 14:35:05 +0500 #4

uhhh isnt that for preventing pre-det. and pinging and to lower combustion chamber temperatures?

Flyhigh1 (Flyhigh1) 2011-05-10 17:23:34 +0500 #5

Exhuast needs to be expelled n not re-sent into intake, the exhaust gases are full of carbondioxide, monoxide etc n oxygen isn't present in amounts required for combustion, so u need fresh air for that (combustion). Btw are u talking abt crank case PVC valve or sunthing?

Xulfiqar (Xulfiqar) 2011-05-10 17:49:23 +0500 #6

yes - sure - but your engine is not right now under the monitoring of any air research board. introducing EG in your inlet would lead to a myriad of other problems. AND your ECU is not setup to work the EGR valve

ahsanonline (ahsanonline) 2011-05-11 09:05:13 +0500 #7

well the ecu does have pinout for a vsv tht might be operating the egr system, its not the emissions im worried about right now, its the drivability factor that i want improved...

Xulfiqar (Xulfiqar) 2011-05-11 13:57:56 +0500 #8

EGR will worsen whatever driveability you have now. The VSV pin on your ECU is for the purge canister vacuum solenoid and not the EGR

ahsanonline (ahsanonline) 2011-05-12 09:19:21 +0500 #9

ahan okay... :s

and what does the purge canister thingy do?
more importantly, how to stop the pinging on hot engine?

Xulfiqar (Xulfiqar) 2011-05-12 14:43:02 +0500 #10

to stop pinging on normal temperature - adjust ignition timing as per toyota spec. and use original heat range spark plugs - I think you are using hot ones.

The purge canister takes petrol vapour from the tank and dumps into the inlet on startup or on heavy vacuum. Its an emmissions reducing device.

ahsanonline (ahsanonline) 2011-05-13 06:21:36 +0500 #11

any idea which plugs are oem for 5afe? il post soon the ngk plugs i have right now.

ahsanonline (ahsanonline) 2011-05-22 14:50:00 +0500 #12

NGK plugs i have right now are BKR6EY-11...

i tested the tps voltages and no matter how i set it, the voltage remains in a 0-3volts window between fully closed throttle and wide open throttle. Isnt that window supposed to be 0-5volts ? Should i replace the tps?

ahsanonline (ahsanonline) 2011-05-26 15:37:27 +0500 #13

anyone??

sami_voodoo (sami_voodoo) 2011-06-06 10:57:45 +0500 #14

I'm not sure about Japanese TPSs, but on Bosch ones, you've got two outputs, one varying between 0.25 and 2.25 volts, and the other from 0.5 to 4.5 volts, i.e. the double of the first. It's to add redundancy. I seriously doubt you'll get the full 5 volts on your TPS. If anything, the ECU will most probably throw out error codes if it ever sees 5 volts.

Xulfiqar (Xulfiqar) 2011-06-06 12:26:00 +0500 #15

The TPS on the 5AFE engine would have 4 pins, one 5V input, one variating output, one ground and one idle switch (which is simply a ground contact to show the ECU the throttle valve is at idle position)

ahsanonline (ahsanonline) 2011-06-06 15:17:59 +0500 #16

yes, the current tps has four pins, VC, VTA, IDL, E2.

what im currently concerned about is the fact that this tps is only capable of giving output in a 3volt window instead of the standard 5volt window on such a toyota system.

even after max adjustment so that idl contact breaks on a 0.8mm movement of throttle, the resistance stays at these values:

fully closed throttle 0.46 kohm
wide open throttle 2.72 kohm

that upper limit is quite below acceptable, there are no sudden breaks while sweeping the tps in its range of motion using DMM.

AM I USING THE WRONG TPS FOR THE APPLICATION?