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ZD30 Engine Problems
The engine does have a boost sensor, but it plays no part in fuel mixture control. The ECU will reduce boost when it gets too high, but this system is very slow to react and boost spikes of up to 25psi are common.
One of the advantages of Variable Geometry Turbochargers, is that they can be controlled electrically using vacuum rather than pressure. The ECU controls a vacuum solenoid using pulse width modulation (PWM) and by rapidly switching it at different pulse widths, it controls how much vacuum gets to the turbocharger’s actuator and in turn how much boost the turbo produces at any given rpm and load. This is very important because it enables the ECU to reduce boost at any time, even under load or when the throttle is partly pushed open.
The ECU can reduce boost to promote maximum EGR flow by reducing intake pressure while opening the EGR valve with the throttle pushed open under light load conditions. This forces more exhaust gas into the inlet manifold and combustion chambers, which in turn reduces peak combustion temperatures and NOx emissions. When this happens, EGT’s rise because there is less cool oxygen enriched air entering the combustion chambers and more hot exhaust gas, further increasing exhaust temperatures.
Any combination of the conditions mentioned above can cause an engine failure due to excessive combustion temperatures, but there are relatively easy and cheap ways of monitoring and controlling these systems. Taking some precautionary measures should reduce the chance of an engine failure or at least prolong the engine’s life. In most cases, modifying an engine or its controls can be risky to say the least, but in this case it’s risky not to.