CDI3 EGR bypass mod

[Alex Crow]

on egr plug, but you can connect them directly on cable near the ecu.

Someone can say me if the 1N4007 diode are ok? I can't find the 1N4004.

http://www.diodes.com/_files/datasheets/ds28002.pdf

Should be fine - similar specs but able to cope with higher voltages.

 

[Alex Crow]

@Alex Crow

I dont need to hide this "emulator" in ECU box so basicly can I connect it directly on EGR Plug and MAF ?

1 Wire goes to pin 5 on MAF
next 3 goes on EGR Plug directly or how ?

EGR valve has live, earth and signal wires. Live is '12v', earth is '0v' and signal is 'PWM' in my wiring diagram.

Live will be something like red/green.
Earth will be brown.
Signal usually grey/some other colour.

HTH

 

[m1lo5]

On my EGR connector there is 4 pins.

1 empty, one red-yellow, one green-yellow and brown-yellow.

 

[m1lo5]

UPDATE

Installed as following:

12V - RED YELLOW
0V - BROWN YELLOW
PWM - GREEN YELLOW
MAF5 on MAF 5 ( there is numbers on each "pin" on maf: 1 2 3 4 5 )

Then resseted all DTC faults.

Cel on, limp ON, DTC: MAF input circut low and HO2S sensor. Same without "emulator".

 

[patxi]

Cel on, limp ON, DTC: MAF input circut low and HO2S sensor. Same without "emulator".

So it appears that the emulator is having no effect on the car.

Either the emulator is made incorrectly or it has been fitted to the car incorrectly.

Can you post a clear photo of your emulator so that the colour codes on the resistors can be seen.

 

[nizam9w2ms]

The Best mod for EGR Delete

It's working good since 2013 until now on my W211 E270 OM647.
Big thanks!

OK, this works on a W211 with CDI3 electronic EGR valve and 648 (IL6 320 cdi) engine.

It satisfies EGR monitoring function over various driving conditions, and also prevents EGR valve open circuit/short circuit etc fault codes.
On road test the car performed very well, with no black smoke but plenty of acceleration on demand, as said, no codes are being logged during mixed road test and period of idling.

What does it do?

R3 gives a path to ground to 'drag down' maf signal voltage as per earlier CDI2 mod. The diode again is also as per the other mod, and prevents the circuit from raising the maf voltage above its natural value.

R1 satisfies the monitoring of the EGR valve, to avoid open circuit codes.

R2 is a balancing resistor, and has a value chosen with the gain of the transistor in mind, to ensure the transistor is fully saturated when on.

The transistor is used as an inverter, to reverse the PWM signal.

The mod should cause no damage to any electronic components on the car, the max current that can flow is through R3, limited to 18ma or so.

 

[laffenxxx]

Will this mod work on om628 ..400 Cdi w463 ?

 

[rossbots]

Decided to give this a run on my '05 C220 CDI. She's a high miler and doing preventative maintenance. First time playing with circuits. Here is attempt 1, will work on connecting it tomorrow. Will go into a little black box with some epoxy.

I have done lots of reading up on this. Has anyone had the EGR loosing boost pressure when the plug is disconnected and this emulator fitted?

 

[Papacha_Man2004]

EGR Mod

Sorry guys, but I have no time to read all the posts here, I read a few, I am having a problem with my w211 from 2003, a 220cdi. It gives me a fault code P2346 something about Exhaust Control Negative Mess Control High, the error comes on when engine hot and running on motorway for a while on cruise control at 70mph, only shows on diagnostic machine, no engine light on and car goes in limp mode, very poor acceleration.I stop the car start again and works fine. The diagnostic machine I used is a Snap-ON Verus Pro from work. I did a search on the internet and found out that mostly could be the EGR cooler blocked. The thing is that I have seen a box on Ebay about 100 pounds to cut the EGR like the ones you guys building here. My question is, worth buying it and install it, some one here tried it, if yes, what happens. Thanks for reading and replying.

 

[Alex Crow]

Not sure about the box from ebay, but the circuit at the start of this thread should fix your problem.

 

[CDR]

Just spent the last two hours reading this and I love it! So this should work on my e320 CDI Alex do you still sell kits?

 

[CDR]

You've got mail.

I've got the parts to make about 5 more.

Any chance are you still making them?

 

[patxi]

Hi CDR,
You are testing our remote diagnosis skills with your question as you don't give many clues about your car's age or configuration - do you know which engine variant it is? My limited knowledge of models sold in USA are OM642 or OM648, there may be others.

Looking back through this thread myself it appears the cars with a straight 6 engine may be OK with this mod, but with a V6 it is unlikely.

If unsure, post your chassis number and someone will decode it and say for sure.

 

[CDR]

Hi CDR,
You are testing our remote diagnosis skills with your question as you don't give many clues about your car's age or configuration - do you know which engine variant it is? My limited knowledge of models sold in USA are OM642 or OM648, there may be others.

Looking back through this thread myself it appears the cars with a straight 6 engine may be OK with this mod, but with a V6 it is unlikely.

If unsure, post your chassis number and someone will decode it and say for sure.

Sorry about that I have E320 CDI 2005 I6

 

[Alex Crow]

Yes it will work with the I6 OM648 engine.

Enjoy.

 

[korgua]

W220 320CDI EGR bypass success

Having poured through this thread for hours and hours I decided it was time to have a go.

I have recently purchased a W220.025 so it has the OM648 engine.

I ordered all the components from CPC farnell.

I made up the circuit board copying the layout of one in this thread.

I had overlooked the wattage requirements so a quick check on google led me to establish the following: Wattage = (Volts*Volts) / Resistance
e.g. the wattage for the 22k ohm resistor on 12v is (12*12) / 22000 = 0.0065W or 6.5mW. This gave me confidence the rated wattage of 125mW was sufficient. I have marked up the actual wattage for all the resistors in red on the photo above. As I understand it, with resistors in parallel i.e. the 1k and 1.8k, the current through each is independent of the other.

I had decided I would add some plug and play functionality – I am the idiot who had to drill a hole to get back into the boot. I would like the peace of mind that if my new soldering skills fail then I can quickly reconnect the EGR plug.

For the first time in my brief ownership I remove the engine covers. The EGR valve is clear to see:

The EGR plug connections are simple enough and I do not need to trace them as I am connecting the Blackbox at the EGR valve.

The MAF connection is simple enough – I put a meter across pin 5 and see there is approx. 1.8v (if I recall correctly) on idle.

I open up the offside fuse box cover located at the bottom of the windscreen.
Based on information in this thread I am looking for the Yellow/White MAF signal wire going into the connector labelled M

I put a meter across this wire and pin5 on the MAF connector – bingo!

I solder a wire on this yellow / white wire and run it to the new blackbox by the EGR.

There was nothing left to do other than make sure the EGR connector was disconnected, the new blackbox connected into the MAF signal wire and the EGR loom.

I started the engine and it sounded no different – I don’t suppose it would do.
I have only been for two brief test drives and I cannot tell if there is any difference in performance. At the end of the day it is a heavy automatic diesel powered car – it would take some notable increases in power to make a noticeable difference.
It is a new car to me so I have no mental record of the same journey to make any comparisons. The car never seemed to underperform but I have only ever driven one W220.
The fuel filter, oil filter, air filter were all changed recently. The car has not smoked in my ownership.
As I understand it this this mod is great for keeping the lungs clean and avoiding costly EGR issues – for that alone I would make the mod.
I think I need to use the plug and play feature to enable and disable the EGR whilst performing test runs on the same piece of road.
Overall I am extremely grateful for the resources in this thread and very happy with the implementation of the modification.
I have no facility to read engine codes at this time so I will report back if there is anything that might be related to this modification.

 

[korgua]

OK - great news!

I had a gearbox slippage issue, now resolved.

This was masking the release of power the EGR shunt provided.

I have tested performance on the same road with and without the EGR. The difference is certainly noticeable, pickup is quicker and pulls more.

My comment in the last post can safely be ignored :Oops: "I have only been for two brief test drives and I cannot tell if there is any difference in performance. At the end of the day it is a heavy automatic diesel powered car – it would take some notable increases in power to make a noticeable difference"

ECU is logging P2121 – Left exhaust gas recirculation (EGR) positioner (Y27/9) wiring

But this is not putting the engine management light on so I assume it can be ignored.

 

[runningonempty]

2007 vito 120
Hi I've had loads of problems with the egr, so i decided to have it deleted from the ecu. engine light has gone but it still runs in limp mod! so im wondering if they have done the job correctly.
The egr is still fitted but in the off position and unplugged.
As well as deleting it from the ecu should the egr valve itself be physically removed and blanked off.?

 

[HITECH]

Absolutely cracking mod Alex. Top bloke for posting the diagram and korgua top bloke for them great pics. A 401 error made me find my way right here. so 1 watt resistors sound enough to use then? Also the biggest question. Is it compatible with my C220 CDI 2.1, 54 PLATE ? Excellent post this btw. No wonder its been getting so many replys.

 

[HITECH]

2007 vito 120
Hi I've had loads of problems with the egr, so i decided to have it deleted from the ecu. engine light has gone but it still runs in limp mod! so im wondering if they have done the job correctly.
The egr is still fitted but in the off position and unplugged.
As well as deleting it from the ecu should the egr valve itself be physically removed and blanked off.?

Outa curiosity what kinda stuff u had happening?. U changed the dpfe sensor? Its a prime suspect for causing egr limp mode. 5 W03 c220s (including my own) needed replacements which all caused sporadic false error codes and limp mode. I actually am just having to replace my own now. Cheap sensors more often than not give u either same fault code or throw up some new ones to lead u up the garden path. If u are to try dpfe sensor buy original Mercedes one.