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EGR simulator


2010/04/26 update

To get more background on what impact this change has on the engine and ECU, read my blog posting on the EGR system.


On the Z22SE forum they developed a circuit to replace the EGR (exhaust gas recirculation valve). This will let the ECU think the EGR is still there, while it isn't.

The circuit looks like this.

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After buying the parts it was time for some soldering with the following result.

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Then the simulator could be mounted in the car. This is the EGR valve.

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I'm going to place the simulator in parrallel. If there are any problems I can reconnect the connector to the EGR (after removing the simulator). If there are no problems after a period of time, I'm going to cut of the connector and solder the simulator directly to the wires.
First the connector has to be removed.

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I stripped a bit of the isolation of the wires (except the middle one) and put solder on them.

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Then I soldered the simulator to the wires. The colors (according to the forum) are:

Pin A: brown
Pin B: brown/blue
Pin D: black/blue or black/white
Pin E: black/red or black/brown

After soldering it looks like this.

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Last step is isolation. As it is a temporary setup for me I put tape on the connectors to prevent water ingress and tiewrapped the simulator to a hook that is connected to the engine.

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To be sure the ECU wouldn't have problems with the circuit I used the diagnosis software to reset the longterm test. All tests will have to be redone, including the EGR test.

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After a testdrive of around 150km the screen looked like this:

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All tests passed, including the EGR test! No logged codes, so it all seems to function fine. After about 2 weeks of driving I will remove the connector and do the final install of the simulator. After that the EGR valve will be removed.

2007/08/26

So time to remove the EGR valve. After removing two bolts it just comes off.

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Then you need to fit the blanking plate. GM part number: 58 50 526 and optionally a gasget (don't know the partnumber, got it with the plate).

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Put the gasget on first.

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Then put the blankingplate on there.

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And bolt it all in place.

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That's it, now no exhaust gasses can get to the intake manifold.

2007/09/26

As an extra I decided to move the EGR simulator over to the cable guide so it is totaly out of view and the connector can be removed.

First I soldered all the wires directly to the simulator instead of parallel to the connector. And ofcourse insulated the connections.

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Then put the whole EGR simulator in shrinktube so it is completely isolated.

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As it is all quite a tight fit I had to tiewrap the cable guide closed. At least it looks a lot cleaner :).

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