SsangYong: Engine Euro 4. Instruction - page 19

EXHAUST SYSTEM

1725 / 1792 / 1913 / 2433 / 2411

TABLE OF CONTENTS

EXHAUST SYSTEM ................................. 2

1. Components ...................................................... 2

E-EGR VALVE (ELECTRIC-EXHAUST
GAS RECIRCULATION VALVE) ............. 3

1. Overview of E-EGR valve ................................... 3

2. Operating range of E-EGR valve ....................... 5

3. Structure of E-EGR Valve ................................. 6

4. New DTCs for E-EGR ....................................... 7

5. Removal and installation E-EGR valve assembly ... 9

EGR COOLER ........................................ 12

1. Overview of EGR cooler .................................. 12

2. Removal and installation of ERG cooler ......... 12

VGT TURBOCHARGER ........................ 13

1. Overview and features of VGT (Variable

Geometry Turbine) .......................................... 13

2. New DTCs for VGT Turbocharger ................... 15

3. Removal and installation of VGT turbocharger ..... 15

VACUUM MODULATOR FOR
CONTROLLING VGT TURBOCHARGER
ACTUATOR ............................................. 19

1. Overview and system layout ........................... 19

2. Removal and installation of vacuum modulator . 21

D27DT + CDPF (Catalytic Diesel
Particulate Filter) ................................... 23

1. Specifications for engine with CDPF .............. 23

2. Overview .......................................................... 24

3. Major changes for CDPF system ................... 24

4. The controls for soot combustion of CDPF

System ........................................................... 26

5. CDPF (Catalyst & Diesel Particulate Filter)

layout .............................................................. 27

6. Soot filtering and burning procedures ............ 28

7. Components of CDPF ..................................... 29

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

2

1725

EXHAUST SYSTEM

D27DTP/D27DT (EU4) SM - 2006.08

D27DTP/D27DT (EU4)

EXHAUST SYSTEM

1. COMPONENTS

The components of the exhaust system for the D27DTP (POWER UP) engine have been changed as follows:

1. E-EGR valve: Controlling the EGR valve electrically and sends the valve location signal to ECU (vacuum

modulator control has been deleted)

2. EGR cooler: Decreasing EGR gas (NOx) efficiently by cooling the EGR gas and let it flow to the intake pipe

3. VGT turbocharger: Increase in capacity and performance compared to D20DT engine

The EGR system has been changed to control NOx more efficiently and the VGT turbo charger has been changed
to increase the engine power. For more details, refer to the next description. The exhaust system for D27DTP
(POWER UP) engine is as follows:

Exhaust pipe
(Exhaust gas)

Air cleaner
(Intake air)

Intercooler
(Compressed air)

EGR gas

(From EGR

cooler)

Turbocharger intercooler

(Intake compressed air)

Intake manifold

EGR

cooler

EGR pipe

VGT

Turbocharger

Exhaust pipe

Exhaust manifold

EGR pipe

E-EGR valve

Exhaust manifold

VGT control

actuator

Throttle body

To EGR

cooler

Exhaust

manifold

Intake

manifold

E-EGR

valve

Coolant

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

3

1792

EXHAUST SYSTEM

D27DTP/D27DT (EU4) SM - 2006.08

D27DTP/D27DT (EU4)

ENGINE

FUEL

I

N

T

AKE

EXHAUST

PRE-HEA

TING

LUB

COOLING

SWITCHABLE

ECU

DIAGNOSIS

1. OVERVIEW OF E-EGR VALVE

The EGR valve for the D27DTP (POWER UP) engine is the E-EGR (Electric-Exhaust Gas Recirculation) valve that
is directly controlled by the ECU with electric signal, while the EGR valve for the D27DT engine is controlled by the
vacuum modulator.

The E-EGR valve is directly controlled by the ECU through the duty control and the valve location signal is sent to
ECU as feedback.

This signal is also used as feedback signal for ECU to control the EGR rate. Also it is used to check whether the E-
EGR valve is properly controlled by ECU.

The followings are the EGR systems for D27DTP (POWER UP) engine and D27DT engine:

E-EGR VALVE (Electric-Exhaust Gas Recirculation Valve)

D27DTP (POWER UP) Engine

D27DT Engine

E-EGR Valve

5V (Engine ECU A82)

Engine ECU (A48)

Ground (Engine ECU A9)

Potentiometer

(Engine ECU A33)

Power (+)

EGR Valve (Vacuum Control Type)

EGR valve

EGR pipe

EGR center pipe

E-EGR valve

EGR cooler

EGR pipe

Throttle body

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

4

1792

EXHAUST SYSTEM

D27DTP/D27DT (EU4) SM - 2006.08

D27DTP/D27DT (EU4)

2

1

4

3

5

The E-EGR valve is controlled electrically, not by vacuum, and duty controlled. Its functions and performance have
been changed as follows compared to the EGR valve controlled by vacuum modulator.

1. Improved response and accuracy by engine ECU control

For the D27DT engine, the vacuum modulator between engine ECU and EGR valve controls the opening level of
EGR valve. However, for the D27DTP (POWER UP) engine, the engine ECU operates the solenoid in EGR valve
only by electric signals.

The response of the EGR valve has been improved as the engine ECU controls the valve directly. Also, the valve is
controlled more precisely by the electric signals.

2. Feedback function of E-EGR valve

By mean of electric signals, the engine ECU can directly control the E-EGR valve and take feedback of the valve
location. In addition to, EGR control feedback signal from the HFM sensor improves the control of E-EGR valve.

The solenoid resistance of E-EGR valve is approx. 8W ± 0.5W at No. 1 and 5 terminals and the overall
resistance at No. 2 and 4 terminals is approx. 4 kW ± 40%.

The resistance (at No. 3 and 2 terminals) changes as the EGR's opening level changes by the electric
signals in ECU.

This signal is sent to ECU as feedback signals indicating opening level of EGR valve.

Basically, the feedback signal for the EGR valve's opening level indicates the air intake volume of the HFM
sensor. (If the exhaust gas is entered into the intake pipe as the EGR valve opens, the amount of fresh air
entered via the HFM sensor decreases. The engine ECU receives the amount of air passing the HFM sensor
according to the opening level of the EGR valve.)

Engine ECU

BATT

3 (potentiometer)

4 (GND)

E-EGR valve

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