SsangYong: Engine Euro 4. Manual - part 20

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

5

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

3. Prevention of EGR valve’s chattering and improved durability

Two valve seats of the EGR valve decrease the chattering phenomenon of the valve occured by the pressure of
exhaust gas when the valve is being opened or closed. As to this, the durability of the valve stem has been
improved.

4. Cleaning function of EGR valve

The solenoid valve is operated when the engine is being turned off and is at mid-high speed to remove the foreign
materials (eg, carbon) accumulated on the valve seat and housing.

5. Learning function of EGR valve location for carbon accumulation

The E-EGR valve monitors the closed and open location of valve before turning off the engine. This value is
analyzed to compensate the changes in valve position occured by the accumulated carbon.

2. OPERATING RANGE OF E-EGR VALVE

The operating range and control range of the E-EGR valve are controlled by control logic (MAP). Followings show
only major operating range.

1. Intake air temperature : approx. -10°C ~ 50°C

2. Atmospheric pressure: Over approx. 0.92 bar

3. Engine coolant temperature: 0°C ~ 100°C

4. EGR valve shut-off when acceleration (engine rpm > 2600)

5. EGR valve shut-off when engine is idling for over 1 minute

6. EGR valve shut-off when vehicle speed is over 100 km/h

7. EGR valve shut-off when engine torque is over 380 Nm

8. EGR valve is normal when there is no DTC related to EGR valve.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

6

1792

EXHAUST SYSTEM

D27DTP/D27DT (EU4)  SM - 2006.08

D27DTP/D27DT (EU4)

3. STRUCTURE OF E-EGR VALVE

1. Valve body

2. Socket

3. Stem

4. Stem guide assembly

5. Valve disc (2) - Diameter 

φ 24 mm

6. Spring

7. Spring disc

8. Solenoid housing assembly

9. Sealing assembly

10. Potentiometer and connector

11. Gasket

12. Bolt

Exhaust System with EGR Valve

To EGR

cooler

Exhaust gas

(From exhaust manifold)

VGT turbocharger

Exhaust pipe

Exhaust manifold

EGR pipe

E-EGR valve

EGR cooler

Internal Structure

EGR pipe

EGR pipe connecting

hole in intake manifold

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

7

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

4. NEW DTCS FOR E-EGR

Engine

Malfunction

Indicator

light

P0405

P0406

P0407

P0408

High EGR
Open Position
deviation

High EGR
Close Position
Deviation

Low EGR
Position Signal

High EGR
Position Signal

- Causes

• The difference between E-EGR position demand

(MAP) value and E-EGR position feedback signal
value is over 15% (the sensor output indicates
E-EGR is open over 15% in the close status).

- Actions

• Measure the resistance of E-EGR valve sensor.

• Check the sensor and actuator wiring harness.

• Check the unit.

- Causes

• The difference between E-EGR position demand

(MAP) value and E-EGR position feedback signal
value is over 15% (the sensor output indicates
E-EGR is closed over 15% in the open status).

- Actions

• Measure the resistance of E-EGR valve sensor.

• Check the sensor and actuator wiring harness.

• Check the unit.

- Diagnosis of E-EGR signal for the followings:

• Sensor signal is high or low.

• Total resistance value: 4

Ω +/-40%

• Sensor output range: 1.2 ~ 4.0 V

• Total sensor resistance: 4 k

Ω ± 40%

• Total motor resistance: 8.0

Ω ± 0.5Ω

- Check pin for the followings:

• Check sensor reference voltage (5V) - ECU Pin

#A33

• Sensor signal - ECU Pin #A82

• Sensor GND - ECU Pin #A09

- Actions

• Measure the resistance of E-EGR valve sensor.

• Check the sensor and actuator wiring harness.

• Check the unit.

- Diagnosis of E-EGR signal for the followings:

• Sensor signal is high or low.

• Total resistance value: 4

Ω +/-40%

• Sensor output range: 1.2 ~ 4.0 V

• Total sensor resistance: 4 k

Ω ± 40%

• Total motor resistance: 8.0

Ω ± 0.5Ω

- Check pin for the followings:

• Check sensor reference voltage (5V) - ECU Pin

#A33

• Sensor signal - ECU Pin #A82

• Sensor GND - ECU Pin #A09

- Actions

• Measure the resistance of E-EGR valve sensor.

• Check the sensor and actuator wiring harness.

• Check the unit.

DTC

Trouble

Limp

Home

Mode

Delayed

Engine

Stop

Torque

Reduction

(max.

20%)

Help

Torque

Reduction

(max.

50%)

Immedi-

ately

Engine

Stop

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

8

1792

EXHAUST SYSTEM

D27DTP/D27DT (EU4)  SM - 2006.08

D27DTP/D27DT (EU4)

Engine

Malfunction

Indicator

light

P1409

P1407

P0402

EGR Valve
Circuit Short

Faulty EGR
Close Position

EGR Valve
Stuck in Open
Position

- Check pin for the followings:

• The E-EGR valve wiring is open.

• E-EGR Pin #1: Power(Main Relay)

• E-EGR Pin #5: ECU Pin #A48

- Actions

• Check E-EGR valve wiring.

• Visually check the unit and replace if necessary.

• Refer to DTCs (P0407 and P0408).

- Causes

• The EGR position is not closed when EGR is not

operated within 50 seconds with the engine idling.

- Check pin for the followings:

• E-EGR #1: Valve power (Main relay)

• E-EGR #2: Sensor (Reference voltage) ECU #A33

• E-EGR #4: Sensor (Ground) ECU #A09

• E-EGR #5: Valve drive (PWM) ECU #A48

• E-EGR #6: Sensor (Signal) ECU #A82

- Actions

• Check E-EGR valve and sensor wiring.

• Visually check the unit and replace if necessary.

• Refer to DTCs (P0407 and P0408).

- Causes

• The E-EGR valve is stuck with it open.

- Check pin (refer to the page 1407)

- Actions

• Check E-EGR valve and sensor wiring.

• Visually check the unit and replace if necessary.

• Replace the ECU if required.

• Refer to DTCs (P0407 and P0408).

DTC

Trouble

Limp

Home

Mode

Delayed

Engine

Stop

Torque

Reduction

(max.

20%)

Help

Torque

Reduction

(max.

50%)

Immedi-

ately

Engine

Stop