CDI3 EGR bypass mod

[delviacv2]

Installed

Installed the emulator today, working grate so far!!

on my car 2005 E320 CDI (USA) the 85/M wire is not yellow/while instead is red/blue, I traced back and is the pin 5 at the MAF sensor plug take a look at the pictures

I used double side tape to secure it in place

for the 2 small wire on the M plug 90/85 I used some telephone wire clips

 

[Alex Crow]

I think they mostly all are red/blue on the CDI3.

Glad it works for you, have plans for a very useful addition to this baby at some point........watch this space (but it will probably be ages).

 

[delviacv2]

Cool, Thanks I will be watching

 

[mercuxio]

85/M Seems to be yellow/white in the few CDI3s I've seen. That's weird. Even most piggyback instructions refer MAF to the yellow/white wire. Maybe it is the US variant?

 

[delviacv2]

85/M Seems to be yellow/white in the few CDI3s I've seen. That's weird. Even most piggyback instructions refer MAF to the yellow/white wire. Maybe it is the US variant?

Could be a USA thing.

 

[mercuxio]

I checked the WIS again. For my car it stated the wire from the actual MAF is red/blue but the wire from the ECU pin is yellow/white. The wires must be joined somewhere.

For yours, the WIS says it should be plain blue all the way from ECU to MAF unit..

I think the wiring color codes are a little off.

 

[delviacv2]

I checked the WIS again. For my car it stated the wire from the actual MAF is red/blue but the wire from the ECU pin is yellow/white. The wires must be joined somewhere.

For yours, the WIS says it should be plain blue all the way from ECU to MAF unit..

I think the wiring color codes are a little off.

Is working grate! That's what really matters
Thanks again to you and Alex.

 

[rpe2]

Well... I've built one.

I'll try and get it in at the weekend..

 

[Alex Crow]

Nice to see the mod working across a range of engines/models, was expecting some tweaking, but a one-size-fits-all would be better.

 

[mercuxio]

Is working grate! That's what really matters
Thanks again to you and Alex.

The credit is all to Alex !

 

[gawdzinner]

very interesting thread!

I have 2 questions, can someone answer for me?

1) I read in this thread that the EGR is to be unplugged after doing this mod. Can the EGR actually be left plugged in since it will not be activated? Or is there a reason why it is unplugged?

2) I see reference to the term "0v", is 0v the same as "ground"?

thanks!

 

[Alex Crow]

1. It will be activated unless unplugged, or one of the wires to it are cut. You can cut the PWM wire in the ECU box, but not the 12v and 0v.

2. Yes, for our purposes here, 0v = chassis ground.

I have not yet tried the mod on a 642 engine, but it ought to be possible with 2x diodes and 2x R3.

 

[gawdzinner]

thanks alex, I will post some om642 information I found on another forum, perhaps members here can help me devise a mod for my north american om642.

one other quick question, I noticed that users install the mod close to the ECU, is there a reason why the mod cannot simply be close to the MAF sensor at the airbox?

 

[Alex Crow]

As I said, it ought to be as simple as adding another diode and R3 to the orignal circuit, and conecting to each maf sensor - there being two.

 

[grinich]

one other quick question, I noticed that users install the mod close to the ECU, is there a reason why the mod cannot simply be close to the MAF sensor at the airbox?

Hi gawdzinner,

With 2 MAF, you have to actuate over 5 wires and they are in 3 different points of the engine. But, fortunately, all of them are together in ECU box and they are covered in it (protected from heat and other actuations). If you put the mod (5 wires) and their connectors (5 wires more plus 5 connectors) in the motor compartment you are taking innecessary risks with heating and putting more difficulties for work in other parts of the engine...

If you want to add a switch a/o a LED it is less difficult to install them in a central situation with all elements (wires, connectors, switch and LED) very close.

It is more 'professional' to do it in minimum space, with protected wires and the wires and simulator (mod) as short and reduce as you can ===> ECU box

BR

 

[Colorado_Al]

I am hoping that this will work with my 03 Sprinter with OM612 engine (USA). Uses the same MAF as early 2000's E320/C320, so I suspect that the ECU is expecting the same signal as the vehicles that you are modding. The EGR is a Wahler 7256D electronically actuated which I think is exclusive to the 01-03 USA Sprinters.

 

[Alex Crow]

I am hoping that this will work with my 03 Sprinter with OM612 engine (USA). Uses the same MAF as early 2000's E320/C320, so I suspect that the ECU is expecting the same signal as the vehicles that you are modding. The EGR is a Wahler 7256D electronically actuated which I think is exclusive to the 01-03 USA Sprinters.

Had a look at those and it looks good - same pins as the Wahler electronic EGR valve we see on the CDI3.

Your suggested pinouts appear correct, so go for it, even if it doesn't work it should do no harm with those resistors fitted.

 

[Colorado_Al]

YOU ARE AWESOME!!
This totally works for my 03 Sprinter with OM612 engine!!!
Thanks to Alex Crow & mercuxio for your excellent work!
It took me about an hour to collect the parts, another hour to build the circuit and another hour to install and test.
The EGR on the OM612 is terrible and prone to failure. This mod is what I have been waiting for!
THANKS!!!

PS-
See my write up here:
http://sprinter-source.com/forum/showthread.php?t=19224
Thanks again!

You may notice that in my build, the transistor is reversed. I used an equivalent to the BC337 that has reversed pin outs (2N2222).

 

[Colorado_Al]

Not sure if this has been covered, but I was just pointed (*by grinich) to a thread started by maipac that has detailed Alex Crow's circuit with a switch that will allow toggle between EGR and bypass circuit, and an LED that will show when the circuit is on or off.
http://www.mbfaq.com/viewtopic.php?f=36&t=188820&start=45
In Spanish however.

 

[grinich]

Not sure if this has been covered, but I was just pointed (*by someone called grinich) to a thread started by maipac that has detailed Alex Crow's circuit with a switch that will allow toggle between EGR and bypass circuit, and an LED that will show when the circuit is on or off.
http://www.mbfaq.com/viewtopic.php?f=36&t=188820&start=45
In Spanish however....

Hi Colorado_Al, I'm here as you...

And yes, this circuit it is working ok in an OM648 (E320CDI) and in an OM647 (E270CDI) as well.

Sorry for Spanish language here but... It is very easy to translate it...

BR