Adding EGR?

I need an EGR system for a LS swap I am planning.
So far my specs are
12200411 PCM
5.3 LM7
Drive by cable
4L60e
4x4


I think I am looking for a bin file for preferably OS 12212156 that has an EGR system monitor in it.
The BIN files I have obtained like the 2002 Chevrolet Silverado Truck Auto LM7 5.3L (12212156) look like they don't have the monitor. (even with the egr system being changed to "enabled", using Tuner pro)
Let me try to explain,
I am using an Autel AL-319(can also use OBD Link software) to see if the monitors are there, they show as not ready or not available.
If they are not available, it seems as though the PCM with that OS doesn't have that monitor.
If they are not ready the monitor seems to be there but just not run yet (of course).

Only BIN I have found with EGR monitor in it has been for a different operating system (2000 CHEVROLET SILVERADO (OS 12205612) that doesn't have a known good XDF file to support it.
It did prove to me that the Autel AL-319 will show the monitor as not ready if it is in there and enabled.

Am I going about this wrong? I do see 1999-2002 Chevy truck (IE Suburban) engines with egr systems on them, on EBay so I know they exist.

Well,
I found a file named 12202088_1GKEK13T31J000000 that has the EGR monitor enabled.
And the XDF file is named 12202088_release

So this is a 12202088 operating system which is supposed to be from 2001 model year.
Now I have to figure out if it has all the correct stuff in it for my 5.3 LM7/4L60e/4x4 and drive by cable, and the Vin attached to the file is bogus so I cannot use that for correct information.
I assume there might be a way to figure it all out but I am still learning (as always). Maybe by the segment numbers?
Any help to speed up my learning curve is appreciated. LOL.

Update,
I found a program called Universal Patcher that shows information in the BIN file easy enough for me to understand.
It shows this:
Platform = GMT800 (Silverado)
Drivetrain Type = 4WD (ATC)
Engine Identifier = 5.3L
Transmission Type = 4L60e

And it shows this:
OS PN: 12202088, Ver: BB, Nr: 1[0000 - 04FF, 0500 - 3FFF, 20000 - 7FFFD], Size: 63FFE
EngineCal PN: 9357822, Ver: AB, Nr: 2[8000 - 13FFF], Size: C000
EngineDiag PN: 9362525, Ver: AC, Nr: 3[14000 - 16DFF], Size: 2E00
TransCal PN: 16264214, Ver: BG, Nr: 4[16E00 - 1BDFF], Size: 5000
TransDiag PN: 16264334, Ver: BA, Nr: 5[1BE00 - 1C7FF], Size: A00
Fuel PN: 16264549, Ver: BD, Nr: 6[1C800 - 1E51F], Size: 1D20
System PN: 9373491, Ver: AL, Nr: 7[1E520 - 1EE9F], Size: 980
Speedometer PN: 9359144, Ver: AY, Nr: 8[1EEA0 - 1EF9F], Size: 100
Eeprom_data PN: 9386530, Ver: DFNN [4000 - 7FFF], Size: 4000
Hardware 9386530

So I think I have my base tune now.

Update,
I just wanted to add some information, so I don't forget.

2001 operating systems that I have found with EGR monitors in them
12202088
12208322

For 2002 I have found this operating system that does NOT have an EGR monitor in it.
12212156

I don't know if it is the operating system itself that has or doesn't have the EGR monitor in it, or if it is the calibration segment for the engine or engine diagnostics.
I would have to find a 12202088 or 12208322 WITHOUT an EGR monitor in it, or a 12212156 WITH an EGR monitor in it to answer that question I guess.
Maybe in the future I will come across one of these but if not then I might assume that there wasn't an EGR system monitor in 2002 due to changes allowing GM to skip installing an EGR system on them.

Quote:

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Originally Posted by 4pointslow

Update,
I just wanted to add some information, so I don't forget.

2001 operating systems that I have found with EGR monitors in them
12202088
12208322

For 2002 I have found this operating system that does NOT have an EGR monitor in it.
12212156

I don't know if it is the operating system itself that has or doesn't have the EGR monitor in it, or if it is the calibration segment for the engine or engine diagnostics.
I would have to find a 12202088 or 12208322 WITHOUT an EGR monitor in it, or a 12212156 WITH an EGR monitor in it to answer that question I guess.
Maybe in the future I will come across one of these but if not then I might assume that there wasn't an EGR system monitor in 2002 due to changes allowing GM to skip installing an EGR system on them.

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12212156 came with EGR from the factory. 2002 Express application.

Quote:

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Originally Posted by 4pointslow

Update,
I just wanted to add some information, so I don't forget.

2001 operating systems that I have found with EGR monitors in them
12202088
12208322

For 2002 I have found this operating system that does NOT have an EGR monitor in it.
12212156

I don't know if it is the operating system itself that has or doesn't have the EGR monitor in it, or if it is the calibration segment for the engine or engine diagnostics.
I would have to find a 12202088 or 12208322 WITHOUT an EGR monitor in it, or a 12212156 WITH an EGR monitor in it to answer that question I guess.
Maybe in the future I will come across one of these but if not then I might assume that there wasn't an EGR system monitor in 2002 due to changes allowing GM to skip installing an EGR system on them.

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I just compared a bin for a 2002 2500 Express 5.3 and a bin for a 2002 Silverado 5.3. I used a tool to compare the data from 0x1FFFF (the end of the calibration section) till the end of the bin and it found no differences.

When you tried to activate the EGR on the other file, did you populate all tables and the DTCs as well?

I'm attaching both files for reference.

Quote:

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Originally Posted by Fast355

12212156 came with EGR from the factory. 2002 Express application.

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Thanks! Maybe I can test a Chevy Express Van BIN and see if the monitor shows just not ready as opposed to not available for the EGR monitor.

Quote:

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Originally Posted by Pulse_GTO

I just compared a bin for a 2002 2500 Express 5.3 and a bin for a 2002 Silverado 5.3. I used a tool to compare the data from 0x1FFFF (the end of the calibration section) till the end of the bin and it found no differences.

When you tried to activate the EGR on the other file, did you populate all tables and the DTCs as well?

I'm attaching both files for reference.

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Thanks! I will test that Express BIN you posted.
I saw no difference in the bins I tested too, I wonder if it is in the diagnostic segment only? If that makes sense?
All I know for sure is the Autel AL-319 or OBDLink and laptop show Not available for the EGR monitor with 2002 O/S 12212156 as opposed to not ready with the 2001 BINS.
I am going to test the Express one you posted, might be what I need. Thanks!

Ok I installed both the Silverado Tune and the Express van tune and here are the results.

Silverado = No EGR monitor.
Attachment 18083
Attachment 18084
Attachment 18085

Express Van = Has EGR monitor.
Attachment 18086
Attachment 18087
Attachment 18088

I'm hoping I didn't mix up the last two pictures that show the calibration segment numbers.
The Express Van is the first 12212156 O/S that I have seen with an EGR monitor.
I'm a bit confused though because it shows the engine being a 5.0 in Universal Patcher.
My setup is going to be 4WD too so I don't think I can use this engine segment or tune itself?
It looks promising though, seeing a 12212156 O/S with EGR monitor.

OMG,
Is Universal Patcher that easy to use?
Did I just do what I think I did?
I clicked on the engine and changed it to 5.3 and then clicked on drivetrain type and changed it to 4wd and saved it.
Did this really change my tune to a 5.3 with 4wd?
I will have to test it to see if it still has the EGR monitor......
Edit: Here is the test results
Has EGR Monitor!
Attachment 18089
Attachment 18090Attachment 18091

Does Universal Patcher really work this way? Is it that easy to change between engine sizes and transmissions etc?
I must be misunderstanding something, the calibration segment numbers didn't change as read by LSDroid.
If anyone can shed some light on this or point me in the right direction please do so.
I'm guessing this isn't working like I think and that I have to do a lot more work to change a tune from 2wd to 4wd or a 5.0 to a 5.3. Not sure though.
Maybe the engine size change in Universal Patcher is just changing the engine displacement in the tune? That would not be a large change.
I have a lot to learn I guess.

I'm interested in how this works out.
I've recently installed BP Automotive's fan upgrade wiring kit in my stock 2001 4x4 5.3 Chevy Tahoe.
As part of that upgrade BP Automotive sent me a 2002 12212156 O/S to flash to my PCM so that the fans would work properly.

With the small amount of testing I've done so far the fans seem to work okay but I noticed my EGR and AIR had stopped working.
EGR was disabled in the O/S they sent me so I enabled it and set all the EGR DTC's to mach my original O/S but the in last test run I still had no EGR or AIR active.
After reading your posts I'm now being to wonder if my EGR can't actually work with 12212156 O/S?

I know there is debate on the pros and cons of EGR but looking back over my logs of before and after the E-fan install I've lost gas millage @55-65MPH presumably with the EGR not working.
So at this stage I'd like to be able to get it working again.

Quote:

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Originally Posted by Kitch

I'm interested in how this works out.
I've recently installed BP Automotive's fan upgrade wiring kit in my stock 2001 4x4 5.3 Chevy Tahoe.
As part of that upgrade BP Automotive sent me a 2002 12212156 O/S to flash to my PCM so that the fans would work properly.

With the small amount of testing I've done so far the fans seem to work okay but I noticed my EGR and AIR had stopped working.
EGR was disabled in the O/S they sent me so I enabled it and set all the EGR DTC's to mach my original O/S but the in last test run I still had no EGR or AIR active.
After reading your posts I'm now being to wonder if my EGR can't actually work with 12212156 O/S?

I know there is debate on the pros and cons of EGR but looking back over my logs of before and after the E-fan install I've lost gas millage @55-65MPH presumably with the EGR not working.
So at this stage I'd like to be able to get it working again.

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Would you be able to post the tune file they sent you?

It's an HPTuner .hpt file, can you work with that or were you wanting a .bin file?

Quote:

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Originally Posted by Kitch

It's an HPTuner .hpt file, can you work with that or were you wanting a .bin file?

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A bin file might be easier, but I'll still take a look at it in HPT.

I've added the .hpt file, see what you can find.

Quote:

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Originally Posted by Kitch

I'm interested in how this works out.
I've recently installed BP Automotive's fan upgrade wiring kit in my stock 2001 4x4 5.3 Chevy Tahoe.
As part of that upgrade BP Automotive sent me a 2002 12212156 O/S to flash to my PCM so that the fans would work properly.

With the small amount of testing I've done so far the fans seem to work okay but I noticed my EGR and AIR had stopped working.
EGR was disabled in the O/S they sent me so I enabled it and set all the EGR DTC's to mach my original O/S but the in last test run I still had no EGR or AIR active.
After reading your posts I'm now being to wonder if my EGR can't actually work with 12212156 O/S?

I know there is debate on the pros and cons of EGR but looking back over my logs of before and after the E-fan install I've lost gas millage @55-65MPH presumably with the EGR not working.
So at this stage I'd like to be able to get it working again.

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With the tune loaded in your pcm you can check the readiness monitors to see if they are marked as Not Ready or Not available. If they are Not Available the monitor is not there.
I assume that if the monitor is not there the system won't work either, but that is just an assumption.
Checking the monitor status can be done with any scan tool with monitor status information I assume. I use the Autel AL319 because it is quick and easy to use for this purpose.
They are cheap and I bought my first one at Walmart, and my second one for work I bought from the internet.
I currently see price at around $29.00 but also around 35.00 depending where they are purchased from. Also, I do not sell them, I just recommend them as a cheap tool that is useful. LOL.

Attachment 18102

Thanks for the info about checking the monitors.
I'm new to HP Tuners and OBDII stuff, I've had more time playing with OBDI and Tunerpro RT.

My Tahoe is at a shop getting the front diff bearings and seals done but as soon as I get it back I'll see if I can figure out the readiness monitors.
I have access to a friends Snap-on scanner, so I'd like to think it should be able provide the info I need.
The scanner (and YouTube) were great at helping track down a faulty FTP sensor that was throwing an EVAP P0446 DTC.

My interest in following this post will be if EGR doesn't work with the 12212156 O/S they've sent me I might be able to learn how to get both E-Fans & EGR working.

Quote:

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Originally Posted by Kitch

I've added the .hpt file, see what you can find.

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Here is your file with the EGR and AIR turned on. I used values I found from an 01 5.3 Tahoe and from the 02 Express 2500 5.3 file. The HPT file you sent me had the EGR Enable switch disabled. That is parameter 210 in HPT software. You need to use the Navigator and search for EGR to find the parameters, at least they were still available in version 4.4.4.

I'm also uploading the same file in bin format along with the matching xdf if anyone sees something I may have misses.

Let us know if this works!

Thanks for taking the time to have a look at it, much appreciated.
Sorry, I should have pointed out the file I uploaded was the original one from BP Automotive and it came with the EGR & AIR disabled and the EGR DTC's off.
I enabled the EGR and the DTC's to match the original file read from my 01 Tahoe, flashed it back to the PCM but data logging while on the motorway was still showing EGR not working.

Thanks for converting it to a .bin format and adding the .xdf.
This my seem like a simple question but can you actually use TunerPro RT to view OBDII .bin files?

Quote:

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Originally Posted by Kitch

Thanks for taking the time to have a look at it, much appreciated.
Sorry, I should have pointed out the file I uploaded was the original one from BP Automotive and it came with the EGR & AIR disabled and the EGR DTC's off.
I enabled the EGR and the DTC's to match the original file read from my 01 Tahoe, flashed it back to the PCM but data logging while on the motorway was still showing EGR not working.

Thanks for converting it to a .bin format and adding the .xdf.
This my seem like a simple question but can you actually use TunerPro RT to view OBDII .bin files?

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Yes. First copy the attached checksum plugin to the TunerPro "Plugins" folder. Then open TunerPro, open the file and the XDF and you are good to go.

If you have HPT, just use the VCM Scanner to see if the monitors show up.

Quote:

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Originally Posted by Pulse_GTO

Here is your file with the EGR and AIR turned on. I used values I found from an 01 5.3 Tahoe and from the 02 Express 2500 5.3 file. The HPT file you sent me had the EGR Enable switch disabled. That is parameter 210 in HPT software. You need to use the Navigator and search for EGR to find the parameters, at least they were still available in version 4.4.4.

I'm also uploading the same file in bin format along with the matching xdf if anyone sees something I may have misses.

Let us know if this works!

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Hello! I have a 2000 Yukon 5.3 LM7 4x4 4L60E. I can pull my BIN with PCHammer but I don't know how to create an XDF for it. I need to 1) delete EGR as I added shorty headers and 2) Add dual electric fans. Can you assist me with this? I cannot find a write up or video anywhere.

Quote:

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Originally Posted by Pulse_GTO

Here is your file with the EGR and AIR turned on. I used values I found from an 01 5.3 Tahoe and from the 02 Express 2500 5.3 file. The HPT file you sent me had the EGR Enable switch disabled. That is parameter 210 in HPT software. You need to use the Navigator and search for EGR to find the parameters, at least they were still available in version 4.4.4.

I'm also uploading the same file in bin format along with the matching xdf if anyone sees something I may have misses.

Let us know if this works!

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Hi there, may I have the matching BIN and XDF files you created but with the EGR still disabled? I see Op originally gave you the HPT file but I need it for use in TunerPro.