First of all let me clear this up first. The vehicle this was done is a 2016 Innova - a people carrier MPV based on the same platform which underpins Hilux/Fortuner.
I have the same 1GDFTV engine in my Innova and hopefully this method should be applicable for all GDFTV applications including 2GDFTV. This i guess is the first "documented" report of a no error full EGR blank on the new engine available on the internet. This method doesn't need remap or any other extra module to accomplish this, all it needs is a full blank plate.
Copying from my blog - http://toyota-d4d.blogspot.com/2017/07/ ... blank.html
---
Finally it's done! Blanking the EGR completely on the new GD engine without using any additional modules or turning it off in a remap. I think this is the first "documented" case of a successful complete EGR blank on the new GD engine.
Blanking EGR is a two step process and one of them steps is a invasive process which is probably going to be irreversible depending on how you do it.
Step 1 - Throttle body plate delete
This depending on how you proceed with it, i.e., carefully and with patience, you can get the screws out without damage and slide out the plate. But me I just drilled the screws out. You can read about it in detail here - throttle plate delete.
Step 2 - Blanking the EGR
This is a relatively easy thing to do all you need is a EGR blanking plate which you need to install it at the rear end of the cast iron exhaust manifold. This prevents exhaust from getting into the EGR system.
Note:
It might be possible to get away without removing the throttle plate if you drill a large enough hole on the plate, probably a 14mm hole. But I would suggest simply removing the plate instead of making a hole in it. Removing the throttle plate (or putting a hole in it) is important because if you do not do that ECU will throw a code.
When the ECU decides to let in some exhaust it will close the throttle (explained in linked post above) and engine sucks in the exhaust through EGR system, so if you block the EGR feed then manifold air pressure goes down as engine gets no gas (doesn't matter if its exhaust or air). ECU throws a code.
Now this is how it works with throttle removed. When ECU decides to let in some EGR it closes the throttle and opens EGR valve but EGR feed is blocked and no exhaust gets in. But now with the throttle plate removed there is no actual throttle closing happening and the manifold continues to get fresh charge air. This fresh air maintains pressure inside the manifold in-spite of EGR feed being blocked. So ECU is happy and doesn't throw a code.
--