On June 3rd I purchased a Smarty Jr.and had the delets from the turbo back. I did add a straight through muffler (wife not happy ). On the 4th left Payette, Idaho towing our 32 ft. Montana 5er, headed to Twin Falls, Idaho. Smarty was set at sw-2, Pod was 99, both timing and torque were set at default. This caibration was done by the shop/dealer that did the delet and install. Mileage check at 243 miles, using 24.4 gals ==9.9 mpg. Terrible mileage and to much smoke (wife really PO'd ). Returing home on the 6th, Smarty set at sw-1, Pod 99, timing/tourque default. 216 miles using 15.1 gal==14.3 mpg. Best towing mileage I've ever got. Still to much smoke. (wife smiled a couple times). Until today, my towing averages have been 10.5 to 11.5, so 14 mpg made me happy (wife spoke to me ). Over all I like the added power, the truck seems to start better and is still stock quiet. But.......I hate the smoke! Coating my bumper and lower fender is not acceptable. I could live with a litte smoke on power demand but not the bellowing smoke that occures when driving at a steady speed on near level freeway. If i can't get the smoke taken care of I'll probably go back to stock. If anyone has suggestions on calibration please help me out. I have not blocked off or unplugged my egr. Stock air intake .

 

My truck smoked like tire fire before I removed the EGR. 25 mph unloaded thru my neighborhood I was blocking sunlight. Truck had a steady haze at highway speed. After disconnecting the EGR I have barely any noticeable smoke all the way up to SW5.

 

2171CTD, thanks for the response. I wondered about the EGR but wasn't sure. I'll start looking for a block-off kit. Although i am ARMY (Viet Nam era) I have always admired the espirit of the MARINE CORPS. Thanks for your serivce to this great country.

 

when you did your delete, did you do anything as far as the egr, unplug it, or leave it plugged in,(for this 450 mile trip) or did you have the spring out and leave it plugged in, (I think thats what we have to do)

 

The EGR has not been altered. I asked the installer if the EGR should be unplugged and he said no, that smarty will take of whats needed. However, when I called him and advised him of to much smoke, he replied, Well, maybe you will have to block off the EGR. You've got my attention on the spring removal, I remember reading a thread about that. I was actually going to order or purchase a complete block off kit. I will re-think this. Thanks.

 

No problem and thank you as well.

My EGR actuator motor is plugged in and zip tied off to the side with the spring removed. Follow the steps in the link. http://www.madselectronics.com/CodeF...EGRDelete.html

 

For an easy test just un-plug the EGR.

 

I believe to just unplug the throttle valve, and the egr cooler

 

Got up this AM, changed program to sw3, T&T to #2, Pod to 60. Truck ran well and guess what, hardly any smoke, I mean about as much as 1 puff on the cigarette. But after reading all the threads on deleting the EGR I followed the Mads EGR delete directions and removed it. As I was disconnecting the cross over pipe I had to wonder if you guys that have done this before were quietly chuckling to yourselves, wait till he realizes he has to unbolt the bracket supporting the center of the pipe. I wrestled with this for quite a few minutes. Then following the advice of using Doorman 555-020 to block off the cooling side. Well, how did he get that freeze plug in there? Now I understand why using the bolt through the plug could be very helpful. Anyway, I gently tapped it into place, not all the way. Truck ran very well. Speaking to the guy that installed the smarty and delets, said I shouldn't run sw3 when pulling your 5th wheel. What do you guys think??? Also, I reprogramed to sw2, T&T to default and Pod to 99. Truck runs great. Only smokes on WOT. I am happy!!! Thanks to all of you and your knowledge.

 

Glad it worked out for ya. I dont tow very heavy, around 7k, but I use SW3 all the time.

 

Bluetek; you 5er is probably what 10-12 thousand #'s?

I was at the auto parts the other day, they heard of doorman, but could'nt come up with a 555-020#, any one have the size of the plug off the top of their head? Do you have to drill the hole, then put a bolt thru it? thanks

 

SW3 is a lot of extra power for the drivetrain when towin.. Unless you have trans mods I would run SW2.

 

I was looking for the Doorman frost plug as well and could not find one at all in our town. I went to Canadian Tire and the size you need is 1.125 inch. The bolt in the middle trick works awesome (thanks mega-engr). Regarding smoke, on the stock and fuel economy tune, I can't get it to smoke at all. On the towing or 70 hp tune, she will smoke when I put the hammer down. I think that might be a little too much power on a stock tranny if you're towing heavy.

I'm all for clean air, but when it chokes down the motor so bad, causes it to not run right and gives **** poor fuel economy, its time for a change. The change I did (and legally, I'm not saying I did or did not), made the truck 100 times better.

 

I just got done on a non-towing trip of about 600 miles and noticed some black haze on my bumper. I have not noticed any smoke though, but have not really been looking either so far... I run SW3 on the Sr...

 

Sabercat, yes the 5er is a Montana 2955, two slides, and probably just what you said, 10 to 12 Thosand lb. I have reset the smarty to sw2, like the way it runs. As for the doorman freese plug, NAPA couldn't cross reference the #. So I called another parts store in Payette and they had 10. I did the drill and bolt thing as Maga-engr suggested, a real good idea. When trying to disconnect the throttle valve, there are two connectors one on the air intake tube and the other on the cooler, they both have the same slide release that is on the throtle valve, buy practicing on them it made it easier for me to get that connector off.
I called H&S this AM to order a egr block off kit (15$), they said we are not taking orders over the phone and didn't offer any other info. Would anyone recommend another source for the egr block kits?