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Tuning the 3.0D 1996 Gen3 and EGR bypass mod

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  • Tuning the 3.0D 1996 Gen3 and EGR bypass mod

    Hi all,
    This is my second Surf, a 1996 3rd gen which came into the UK in 2003 with 85,000km on the clock. It has stood for four yeras before the importers decided to sell it at 87,000km I was lucky and picked it up for £3,500. Only one thing wrong and that was the wiring inside the 4wd selector lever was all chewed up and so they had twisted the wires together to make it permanently 4wd.
    £34 later and a new one is fitted and working beautifully.
    I have a good relationship with a local (Bromsgrove) chip tuning co who have a 4wd rolling road. Both he and my mechanic told me that bypassing the EGR was a great idea which I did about a month ago and cannot believe the difference! I have been assured by my local Toyota dealership mechanical department, and my mechanic that the engine and head should have no problems with the modifications I am looking at. Time will tell I guess.
    Anyhow, it's off to have some sort of wizardry done tomorrow (14th September 2007) at chipped UK. He reckons up to 40bhp more!!
    I'll let you guys know what he does and more importantly I am going to ask him if we can do three roller runs. One with the EGR reconnected, one with it bypassed and one after he's finished with boost pressures and wastegate thingys. We should then get an idea how much of a difference the EGR mod gives and also, just what we can get from the 3.0D without taking spanners to it.
    I will post the resuts here.
    Also, next Friday (21st) it's off to have a powerflow twin exit exhaust system fitted. From the single downpipe back, it will have the massive silencer removed and replaced with a flowthrough silencer, then at the rear of the axle, it will be split into two and have a pipe running to each side at the back with twin tailpipe trims on each side. A surf with a quad pipe exhaust?? Oh YES! Maybe later, I iwll change the downpipe to a 3" but I'm told it won't make a great amount of difference.
    The designer says I can have it as loud as I want it to be and seeing as they are an MOT testing station too, he will make sure it's legal and MOT proof.
    I'll let you know how the tuning goes first and then the results from the exhaust mod.

  • #2
    I hope it goes ok for you mate. I hope your CAM-BELT is fairly new.
    (\__/)
    (='.'=) SQUIRREL MUNCHER GRRRRRRR
    (")_(")

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    • #3
      hello were in Bromsgrove is the garage you are using be nice to find local garage that knows what they are talking about

      Comment


      • #4
        Hi there

        i to have a third gen and bypassed the egr valve but didn't notice too much difference did you do this by removing the vacume pipe on top of the valve or is there another way to do this....also is yours intercooled or not....would be really interested in how your car performs after you finish as i live local and would concider similar mods for mine.

        Cheers
        Mat
        Nut in a Truck

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        • #5
          Originally posted by rowleav
          Hi all,
          This is my second Surf, a 1996 3rd gen exhaust mod.
          Then get it up your profile, instead of , or at least in addition to the "other thing" that you have there.

          Bogus
          Сви можемо

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          • #6
            Its going to look like this powerflow then
            Attached Files
            I HAVE FOUND JESUS he was behind the sofa

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            • #7
              3.0D 1996 Gen3 and EGR bypass mod

              Me thinks thats one surf that aint gonna see any mud!!!!

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              • #8
                cam belts supposed to be changed every 100,000 km or every 60 months which ever comes first, regardless of standing for 4 years,

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                • #9
                  Andy(rowleav) is having trouble logging in on the forum but will reply to this thread as soon as he can
                  https://www.facebook.com/groups/henpals/

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                  • #10
                    Originally posted by davemaxx
                    cam belts supposed to be changed every 100,000 km or every 60 months which ever comes first, regardless of standing for 4 years,
                    An old CAM BELT is not good on a ROLLING ROAD. My mates RS2000 went BANG due to this. VERY COSTLY MISTAKE
                    (\__/)
                    (='.'=) SQUIRREL MUNCHER GRRRRRRR
                    (")_(")

                    Comment


                    • #11
                      To everyone

                      Hi all,
                      Thank you to everyone eho has responded.
                      I'll also respond and in order of the replies.

                      Firstly then to Marky.
                      Marky, thanks for the response and the advice about the cam belt.
                      I did have my mechanic look at this and he said it was fine, but that we would change it shortly anyway as a precaution. Not a huge job on a Surf, so hopefully sometime this week.

                      Big General...
                      Hi!! Nice to know you are in Bromsgrove too. Aston Fields Service Station. Roger Hill. Very laid back, but knows his stuff and I have never had a cause to complain. Also, Westlands Toyta on Buntsford Hill are very customer friendly and have sourced the bits and pieces for mine with a very professional and friendly service. Good point of contact is Gavin in the spares dept.

                      Fatmat...
                      The difference is quite noticeable but it's not going to throw you to the back of the seat. Main difference is that there is absolutley no smoke at all now. Better response at lower throttle openings too. You could say a little more midrange torque too. There is a possibility that if you didn't notice a change and if you're still throwing out smoke under load, the EGR valve itself may be stuck partially open. You'll need the spanners out then. Best way to see your smoke is at night, at the lights. Pull away hard and glance in the rear view. You would see the smoke in the headlights of the car behind you.

                      Bogus...
                      You are SO right! I am SO bad! I used to have one, I did, I did. It was...well....alright I suppose. Problem is, I'm afraid to change anything really to do with the profile. This is where Richard (Stormforce) came to my rescue.
                      I noticed my email address was wrong, so I changed it and instantly lost the ability to post, reply, and look at the image that Kiowa sent. I tried to email using the contact email for the forum but didn't get anywhere. I created a new profile but never got an activation email whther I used my own or a web based address. I have no spam filters on either. Anyway, Koi and Richard sorted me out (thanks again guys!) and I'm back. What to do....do I or don't I....?

                      Kiowa....
                      Yes!! Spot on and the same colour as my Surf! Same trims too that I'll be having. Only difference is that the boxes won't be at the back as far as I can tell. How does yours sound? Do you have any wav's anywhere I/we could hear? Man, that looks awesome!
                      Did it make any difference to your performance or fuel economy?

                      Steve...
                      You HAVE to be kidding me right?
                      www.4x4funday.co.uk Been to about six or so now. This Surf hasn't yet. Only just got it, but you can bet your life it will be...er....er...ah yes.. 'Tested'
                      My previous surf, also a 3rd Gen 1996 was excellent in the quarry, so i'll be off to have some fun, but not the sort of fun the real big boys play at, like no deep pools of water. Because of the sand at the quarry I go to, I avoid getting it into the sensitive parts.

                      Davemaxx...
                      Bang on buddy. Even more reinforcement that I will do this before the rollers.

                      Stormforce....
                      As per the emails, you are a goodun' Much appreciated.

                      Marky...
                      The third warning I have received about the cam belt. I have postponed any further rolling road ideas now until its been changed. Thank you. I am a newbie and all this information form you guys is very well received.

                      So, to end. I'll tell you what has been done so far. As per the original post...
                      We didn't roller it yet because its the first Surf ChippedUK have done and there are limitations. A bleed valve was fitted before the wastegate valve and the ECU was remapped with only a very small update. These so far have had only a minor effect in increasing power. What I do notice though is that only 1" of throttle is needed now to do what half throttle did before. Don't get me wrong, it's a boost, but nothing like I expected. Fuel ecomomy seems better so far as only a very light throttle is required now to get up and running at a healthy pace. Jayson at ChippedUK is still working on the project and has managed to get a load of information from other tuners regarding adjustments to various things. Can't tell you yet, but I will as soon as I know anything.
                      Also, I replaced the standard air box with a performance cone filter and that made absolutley no difference whatsoever apart from horrendous noise. Not induction roar, but a very loud hiss like compressed air being relased. Stock one refitted.

                      Finally... Koi....
                      Thank you for resetting my profile and will it go belly up again if I change anything?

                      Keep you all posted and thanks again to everyone!
                      Last edited by rowleav; 17 September 2007, 17:35.

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                      • #12
                        My mate used to use a ROLLING ROAD & he's seen many an Engine blow its top. I'm glad you took the Advice mate & GOOD LUCK.
                        (\__/)
                        (='.'=) SQUIRREL MUNCHER GRRRRRRR
                        (")_(")

                        Comment


                        • #13
                          Glad i could help Andy.You should be ok to change your profile now everything has been reset.Gupster had the same thing a few weeks back also so your not alone
                          https://www.facebook.com/groups/henpals/

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                          • #14
                            Kiowa's quads

                            Hi Kiowa,
                            I did send an email to you but I'm not sure it got through.
                            Could you post a couple of the underside showing how you routed the pipework?
                            The fitters by me are looking at replacing the main sliencer and splitting the pipe rear of the axle to straight pipes to the back. With your silencers at he rear, do you have pipes only foward of them?
                            How does it sound?
                            Any difference in performance or fuel ecomomy?
                            And finally, what was the cost of the conversion?

                            Hope you can advise. I guess this is your own Surf and you have something to do with Roughtrax.
                            Sorry for being so green, but I don't know many here yet.

                            All the best.

                            Andy

                            Comment


                            • #15
                              Dont Forget to modify the Air intake filter

                              those modifications really good for ur Surfie boy there, anyways to get even more power out of all the modifications you aformentioned dont forget to change the air Filter and tha air filter assembly with a bigger or a more free flowing one too.. Remember, if youve modified the exhaust, u should modify the intake to get the full potential of ur modifications..

                              Good luck and Enjoy

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