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EGR Ugly fix – 2002 -2006
Just saw it on another forum – For all with Det 60 – 2002 through 2006 14L AND 12.7L
On sale through 3/29/16:
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7 Replies
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Who has this? I think Jon, you did this correct? Curious here.
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I have added this to several coaches, and typically very good feedback, exhaust is cleaner, better MPG and most of all we stop EGR from dumping on #6 hole with potential of damage…..
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Jeff,
So if one was to buy one, and we are in at your place for service you can install correct? Will be there this July for sure!
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I have one installed but another member also did some work on my DDEC to negate the need. He programmed my EGR to operate at 3200 RPM and to stop operating at 3400 RPM and above.
I plugged the EGR tube to prevent any exhaust gas leaking past the valve from ever reaching the engine.
In case anyone is tracking what impact that has had, the initial change was a .2 to .3 improvement in mileage. Mileage prior to any change to the EGR was 5.9 MPG. After the Ugly Fix / DDEC change mileage went to approximately 6.2 MPG.Since the DDEC change which included some tweaking of fuel flow the mileage and the subsequent blocking of the exhaust from the EGR valve mileage slowly crept up and stabilized at 6.4.
The mileage values were calculated based on 7,000 to 10,000 blocks of travel and fueling. A lot of factors impact mileage so if you want to establish a baseline for comparison you need at least that many miles and you need to be as consistent as possible in your driving. I have a 53,000 pound coach and almost always towed an H2 Hummer. That has changed to a lighter toad by about 3500 pounds but only for a few recent trips.
I drive at 61-62 MPH. I leave the retarder master switch on, but only use the retarder stalk to slow down such as at ramps, long downhills, or in traffic. The rest of the time the coach is on cruise control.
Mileage on a per tank, or even several tanks of fuel is inaccurate. I have had one or two fueling events in which the mileage calculated out as high as 7.4 MPG. Some as low as 5, variations that could be attributed to inconsistent fueling (I milk every last drop I can into the tank, but I can’t change the slope of the fuel island or explain why sometimes it takes a lot and other times it takes less. But any block of about 5000 miles that I select appears to be very close to a similar block of 5000 miles. I ignored the impact of generator and Webasto operation because we had no instances of extended use of either. Based on their hours of use if I added the estimated fuel useage into the equation it would only add a few hundredths to my overall mileage.
Bottom line is the EGR is in my opinion damaging the engine, and anecdotal evidence suggests strongly the #6 cylinder suffers damage from the grit in the exhaust that seems to be concentrated there. I think, but cannot prove that my slow increase in mileage after disabling the EGR was because the engine was cleaning itself up from sooting due to the EGR. One positive difference is my engine oil remains a golden color longer, and even as many miles as 3500 it still is a dark golden color, as opposed to the previously rapid black color.
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We put the Ugly Fix on our coach 15 months ago and have about 30,000 miles of experience with it so far. I drive faster than Jon but have seen similar results. Fuel mileage has increased .3 to .5 mpg. We have not performed the other modifications that Jon has done.
The Ugly Fix replaces the atmospheric pressure sensor and tells the ECM that the engine is operating at or above 10,000 feet of elevation. This causes the ECM to turn off the EGR valve and open up the turbo charger vanes.
Installation is simple but it helps to have a skinny person with long arms. I’m neither but I still got it done. The atmospheric pressure sensor is located under the intake manifold. Jeff employs a couple of fine young men that are skinny, have long arms, and seem to be able to squeeze into any location of a coach.
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We had it installed also without the programming that Jon has!! Couldn’t tell any dfference in the mpg.
Cheers… Diane
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Some engines have been programmed (from the factory apparently) so the EGR is functioning all the time regardless of altitude so the Ugly Fix will not work.
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