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**budweiser** · 24 March 2015, 01:54

i did removed the egr, but never thought about the rest, sorry for not helping.

**tweak'e** · 24 March 2015, 08:08

i havn't done it but done it on other engines.

what you need to look at is th small butterfly. it has an actuator with two parts.
need to work out what does what with it. one will get vacuum for it partly close for egr. most likely one or both will get vacuum for engine shut off.

vacum is control by the vsv's. i simply connected a light and drove it around to see when it tuned on/off. or you could T a vac gauge in to the vac lines.

if it requires vac on both parts of the actuator for engine shutoff, find the vsv for engine shutoff and connect both vac hoses to it. disconnect/block the egr vsv vac hose.
if you just disable the egr vsv you may loose engine shutoff and engine runaway protection

**Lewd Lux Lover** · 24 March 2015, 10:28

Thanks tweak'e thats great info.

I have read so much on this now and its getting clearer in my muddy mind. I have even read some posts by yourself many years ago on forums on this subject..

Let me see if I have this right then.... So the small butterfly is the one that controls shutdown and the big one is the egr one? So work out how to keep the small one open all the time but for shutdown and remove the big one and we should have a somewhat compromise? Still able to shut down smooth but with little or no restriction in the main channel. So now we just need to know what pipe does what....

**tweak'e** · 24 March 2015, 10:34

no.
big one is control by the throttle. the small one does the egr and the shutdown.
the small one closes halfway for egr and closes fully for shutoff.
can't remove any butterflies without stuffing up the smooth shutdown.

**Lewd Lux Lover** · 24 March 2015, 15:37

Ah right, great. That puts a bit of a clearer picture on it. I dont much care about smooth shutdown to be honest. By all accounts some people dont notice it has changed and others say it just stops with a jolt. Like any other diesel I have ever owned (pre 2001 obviously) this is fine by me. I will check the engine mounts for wear when I inspect and grease the prop etc.

So... I will remove the two plates as per the online instructions I have found but what then happens to the three vac pipes I will have with empty ends? No one seems to say what they do with these..Maybe because its obvious you block them all but i am not a mechanic and am swimming in dark waters....

I have two coming out of the throttle plate and the one that operated the egr. I presume I block off the egr one but what about the other two? link them? block them? What do they do? Control the one butterfly? or does one do something else?

Would I be right in thinking that once the plates are removed that we can pretty much take all the vac valves and hoses off and block it all up? Or is there something connected to the fuel pump or some other thing that needs pressure or vac? I read that the 1kz will run happily with no intake mani whatso ever so I kinda want to strip off all the pointless stuff under there associated with these systems once they are removed. Less stuff cluttering up the intake side will help with engine bay temps as well I would have thought.

Cheers for any further insight.

**Lewd Lux Lover** · 24 March 2015, 15:45

Also what does the big one controlled by the throttle cable do? If the small one sorts egr (half) and shutdown (closed) what does the big one take car of out of interest? is it the main way in which the engine would protect against runaway death? In which case could you not just remove the small one and keep the big one? Apparently the small one just unscrews where as the big one needs drilling. None of it hard graft but I am after the most effective way to maximise this mod. Not just pull it all out because I couldn't find a more subtle alternative. If the small one can be held open but for shutdown I would be tempted to leave them there but its conter intuative to leave it there restricting air flow. That will just end up with hotter temps average.

I never knew they put this kinda stuff in derves so its all new info to me.

**Lewd Lux Lover** · 24 March 2015, 17:26

I just found this on a random forum page....

''The 1KZ-TE would work much the same as the 2L-TE and the two vacuum hoses would operate the diaphragm. Lower would get vacuum at idle so it would partially close the butterfly to allow EGR gasses through and the top one would get vacuum at shutdown (in conjunction with the lower) to close the butterfly completely.''

This was nifty nev on toyota 4x4 forum.

Would this not lead me to believe that you connect the hose that was on the egr to the top hose on the throttle plate and block the lower one I should be able to have no egr restriction at idle while still retaining soft shutdown and runaway protection?

Where does the vacuum for the egr come from? could it be this simple? I wont start cutting metal out unless I have to. I just want to stop the butterfly restricing the air flow because it thinks the EGR is still pumping gas into the manifold. I dont need or want to remove them but I will unless I find a work around.

at the same time this post of nev's does suggest that if you remove the butterflies then all three hoses are redundent and can be blocked.

**Lewd Lux Lover** · 24 March 2015, 18:05

right hold all that. It must be different for intercooler equipped cars...

I have had another bloody good look and worked out that all I have to worry about is two tubes. One was connected to the egr. I will block that.
The other is connected to an actuator that is connected to the small butterfly. This is then connected to the fuel pump and must control the soft shut off and the half opening for the egr.

The other two tubes I as worried about are going into the intercooler. One must take a reading pre throttle body and the other after as they have a hole each side of it. Cutting it out would deffo screw with whatever they are reading the difference between so I dont think I want to mess with that yet as I dont know what it is. any help there would be appreciated.

So as it stands with the engine off that valve is in the open position where i want it. Am I right in thinking that if I just slip the push rod out of its coupling I have effectively disabled the engines ability to control this valve but the engine wouldn't know it?
As such it could go on supplying pressure to it when it thought it should but the valve would stay open all the time regardless. No restriction from 1/2 open egr gasses, no soft stop but still somewhat protected from a runaway situation because of the main throttle body still being there...

**Lewd Lux Lover** · 24 March 2015, 18:34

It looks like the later versions with an intercooler were simplified as there are many less vsv's and pipes than all the guides have in the bay..there are only two around the intake area full stop. One on the butterfly, one on the egr. Both these pipes seem to join up into one and go to the big nobble on front of the fuelpump. Would it be fair to say that the actuators probably operated in tandem opposite each other? So when more vac was present (ie less fuel being drawn) the egr would open as the butterfly closed to 50%? This would make sense but I am no mechanic....

As it stands there is only one hose going to the small butterfly actuator. This has been blocked with a screw. The other hose that went into the egr has also been blocked. The egr pipe itself has been taken off and two plates made to be put on.

As I understand it this means I still have some protection from runaway with the large throttle body but the small one is disabled and blocked open. I should get most of the benefits of actually chopping it out without having to. Obviously its still there in the way but its not active anymore. It would be great to be able to get a vsv that only operated under full vac so it closed on shutdown rather than varying its position based on the amount of vac shown by the pump.. I will research this if shutdown is too harsh. A one way actuator set to work at the vac present on shutdown. A vac guage on the pipe would give me this reading and then I could match this to one off the shelf maybe... hmm

Unless anyone can add anything I will report once the rest of the work is done and I drive it. I expect no difference in real terms but if its still got a nice clean intakemani in another 50k you'll know it was worth doing...

**tweak'e** · 25 March 2015, 07:21

i can't quite make head or tail of it.
can you post some pics of it all ?

**Lewd Lux Lover** · 25 March 2015, 08:30

I will certainly do my best.

**Jameswallace** · 25 March 2015, 08:51

Ive not read all posts but my friend had his truck (kz-te) run away last week when the spill valved stuck shut. Engine at full rpm key would t stop it, pulled fuel hose off in the end as nothing else would stop it.

There is a vaccuum thing that will kill the engine in any scenario at the rear of the rocker cover..

**Lewd Lux Lover** · 25 March 2015, 09:06

How's this ?

As you can see there is much less gubbins in the way than all of the other pictures of 1kz intake areas I have seen. Only two actuators and only really one vac signal that splits into two. The egr solenoid is just out of shot under the hose there.

So what do you think? Simple way to retain all the original parts, not affect any other system and lose the restriction of the small butterfly?

Will this thread be searched out by people with intercoolers from factory over the next few years and see a light bulb or will this just be another step on the road to understanding?

**budweiser** · 25 March 2015, 12:15

http://www.hiluxsurf.co.uk/showthrea...&highlight=egr

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1KZ-te EGR and butterfly removal. Opinions/advice.

1KZ-te EGR and butterfly removal. Opinions/advice.

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