EGR + crystal meth =

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MissahPapaJ

Snack Lah Bler!!!!
Joined
Oct 26, 2024
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California
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Can anyone tell me what in the crystal meth is going on here, looks like some back woods Montana people did some handy work to the EGR system looking through FSM and schematics for the EGR and exhaust system I feel like I’m missing something. This is a 96 and I would like this not to be as ugly of a “fix” as it isis, cause it looks like it’s reaping hell on the harness in that area. If anyone could show me how is supposed to look so I can find parts to remedy this abomination of a repair… that would be great.
 
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Can't tell you what goes where (mine's a 94), but I agree, the PO or whoever did that should not have had access to tools!
 
Can't tell you what goes where (mine's a 94), but I agree, the PO or whoever did that should not have had access to tools!
How’s your EGR piping routed. Pics would be great. I’m now wondering WTF I’m guessing the engine assembly was swapped at some point and the powers that be decided it was the fix.
 
Where that port ( block off plate ) is in the picture looks to be solid on my head, and they re-routed the EGR pipe across the top of the valve cover. The plot thickens. It passes CA smog the way it is. No check engine lamp. But that pipe is in the way for sure and it’s too close to the heater control valve and looks to be cooking my engine harness.
 
Mine’s long gone, but used to come off of EGR and then down to a port on the head on the driver’s side…

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Mine’s long gone, but used to come off of EGR and then down to a port on the head on the driver’s side…

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That blocked off port in your photo is what looks to be tapped but doesn’t have a center hole in my last photo so I’m guessing this head is for a market that wouldn’t have a EGR but someone made it “work” did all 80 series in the US have EGR systems? I assume so. I don’t throw any EGR related codes so I guess I’m stumped for now but hopefully someone comes through with some knowledge.
 
It bolts to the back of the head I believe.
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Here's a pic with a block off plate as EGR delete's seem somewhat common.
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See my last pic it looks factory non-equipped so I’m wondering if it’s a head or engine from a non-US market non EGR equipped area, I know AUS 1FZ’s didn’t get EGRs so now I’m wondering about Canada and Japan. The engine bay doesn’t scream swapped to me but I’m probably wrong.
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It’s solid like it was never machined, at first I thought someone shoved a steel stick plug or something but scraping across that area with a long pick I realized it was solid aluminum there
 
Anyone with another 80 near your area? Wirth looking at another 80 to get an idea.
 
That's interesting, certainly looks like that boss was never drilled. Looking at your pictures, the head does look a bit cleaner than the rest of the engine. Someone do a headgasket and end up swapping on some weird aftermarket/repop/non-US head?

My 96 has the factory EGR, but I do get some weird fuel filter diff/trans breathers lol

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That's just....wow. I'm impressed you don't get a code. "If" the EGR actually works, pulling from the exhaust pipe like that, how does the temp sensor register properly? It would suck if you disconnected the battery and reset the monitors then had it not set again.
As Ghetto as it is, someone put some thought into it. Probably during reassemble after the head replacement. It would be more like "OH". we cant bolt this on.
This also make me wonder what this head fits. If its even for an FZJ.
 
That's just....wow. I'm impressed you don't get a code. "If" the EGR actually works, pulling from the exhaust pipe like that, how does the temp sensor register properly? It would suck if you disconnected the battery and reset the monitors then had it not set again.
As Ghetto as it is, someone put some thought into it. Probably during reassemble after the head replacement. It would be more like "OH". we cant bolt this on.
This also make me wonder what this head fits. If its even for an FZJ.
The battery has been disconnected multiple times, everything is working with the system as ugly as it looks but I’m about to delete the system.
 
That's just....wow. I'm impressed you don't get a code. "If" the EGR actually works, pulling from the exhaust pipe like that, how does the temp sensor register properly? It would suck if you disconnected the battery and reset the monitors then had it not set again.
As Ghetto as it is, someone put some thought into it. Probably during reassemble after the head replacement. It would be more like "OH". we cant bolt this on.
This also make me wonder what this head fits. If it’s even for an FZJ.
Temp sensor is behind the flow of EGR passage through the intake so all it has to do is see a heat change during EGR activation.
 
I’m going to partially delete the EGR the smog tech I go to in my area isn’t paying attention so I’m just gonna delete it.
 
Temp sensor is behind the flow of EGR passage through the intake so all it has to do is see a heat change during EGR activation.
Correct. What amazed me is the temp difference pulling it from the head vs just past the cat and the system being ok with it (so far). My 96 has had a history of temp codes starting from about a year old. 280k and a couple of decaids later, everything new including engine and the problem still exists. Pops the code about once a year (same as all the dealer paperwork I got with it). Make me wonder if the egr system is happier sampling the exhaust from there.


EDIT. Answered my own question with a bit of reserch. heres a clip from some of my findings.

EGR is the main source of carbon deposits in the intake paths and on the valves — pulling from after the cat means the gas has already been through the three-way catalyst, so it's cleaner (less unburned HC/soot) before it gets recirculated into the intake tract and onto the intake valves.
 
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Correct. What amazed me is the temp difference pulling it from the head vs just past the cat and the system being ok with it (so far). My 96 has had a history of temp codes starting from about a year old. 280k and a couple of decaids later, everything new including engine and the problem still exists. Pops the code about once a year (same as all the dealer paperwork I got with it). Make me wonder if the egr system is happier sampling the exhaust from there.


EDIT. Answered my own question with a bit of reserch. heres a clip from some of my findings.

EGR is the main source of carbon deposits in the intake paths and on the valves — pulling from after the cat means the gas has already been through the three-way catalyst, so it's cleaner (less unburned HC/soot) before it gets recirculated into the intake tract and onto the intake valves.

For what it's worth, if memory serves, the EGR tests built into the cruiser computer aren't particularly smart, and the system isn't particularly good. It's pretty easy to defeat in a way that most likely wouldn't alert a smog tech. I've never felt any regret about gutting mine, and I've never thrown a code. You could probably end your temp codes by bypassing the system with a "test plug" resistor. I think I remember 4.7k being the value that's often recommended, but you might want to search that. The previous owner of my rig didn't understand the difference between 4.7 ohms and 4.7k ohms, and couldn't make it work. 😆 Only off by a factor of 1000.
 
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