E-EGR SYSTEM

1793-00

E-EGR SYSTEM

GENERAL INFORMATION

1. SPECIFICATION.................................... 3

OVERVIEW AND OPERATING

PROCESS
1. OVERVIEW............................................ 4
2. OPERATING PROCESS......................... 8

CONFIGURATION AND FUNCTION

1793-12 EGR COOLER ASSEMBLY.......... 12

REMOVAL AND INSTALLATION

1793-12 COMPONENT.............................. 15
1793-05 E-EGR PIPE................................. 16
1793-12 E-EGR COOLER........................... 17
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1. SPECIFICATION
Item
E-EGR valve Motor EGR response time 50 ms
Driven by DC motor
Valve EGR gas flow rate 120 kg/h
E-EGR cooler Cooling capacity 8.3 kW or more
Cooling fin type Wavy fin
Cooler type U-shaped
E-EGR bypass valve Solenoid valve Drivien by Vacuum
(Solenoid valve)

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1. OVERVIEW
1) E-EGR Valve
The E-EGR (Electric-Exhaust Gas Recirculation) valve recirculates some of the exhaust gas to
the intake system, and it lowers the combustion temperature by increasing the CO2 content in
the intake air to reduce the emission of NOx.

▶ Benefits of E-EGR valve

- Improved accuracy and response through electric control
- Feedback function (Potentiometer)
- Preventing chattering of EGR valve and improved durability
- Self-cleaning function

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2) Component

HFM sensor

For the control logic of HFM sensor, refer to

"Engine Control" section.
Used as a main map value to control the
EGR. The coolant temperature, engine rpm,
engine load, intake air temperature
(HFM: decreased at 60℃ or more),
atmospheric pressure (atmospheric pressure
sensor: altitude compensation) are used as
auxiliary map values.

EGR pipe

Transports the exhaust gas from the EGR

cooler and EGR bypass valve to the intake
duct.

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E-EGR valve

Receives the electric signal from the ECU to

control the valve.

E-EGR cooler and bypass valve

EGR EGR bypass

cooler
The cooler lowers the high temperature of the
exhaust gas and the bypass valve directly
supplies the exhaust gas to the intake duct
without passing through the EGR cooler to
reduce the emission of exhaust gas before
warming up the engine.

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2. OPERATING PROCESS
1) Schematic Diagram

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2) Input/Output Devices

3) Control Logic
The EGR system controls the EGR amount based on the map values shown below:
※ Main map value: Intake air volume
※ Auxiliary map value:
- Compensation by the coolant temperature
- Compensation by the atmospheric pressure: Altitude compensation
- Compensation by the boost pressure deviation (the difference between the requested value
and the measured value of boost pressure)
- Compensation by the engine load: During sudden acceleration
- Compensation by the intake air temperature
The engine ECU calculates the EGR amount by adding main map value (intake air volume) and
auxiliary map value and directly drives the solenoid valve in the E-EGR to regulate the opening
extent of the EGR valve and sends the feedback to the potentiometer.

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(1) Operating conditions

- Intake air temperature: between -10 and 50℃
- Atmospheric pressure: 0.92 bar or more
- Engine coolant temperature: between 0 and 100°C
- When there is no fault code related to EGR

(2) Shut off conditions

- Abrupt acceleration: with engine speed of 2600 rpm or more
- When the engine is idling for more than 1 minute
- Vehicle speed: 100 km/h or more
- Engine torque: 380 Nm or more

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1) E-EGR Bypass Valve Overview

The EGR gas enters to the intake manifold through the E-EGR cooler.
The major function of the EGR system is reducing the NOx content in the exhaust gas.
The opening extent of the valve is controlled accurately by the E-EGR valve, and the EGR rate
is also controlled precisely by the feedback function.
But lowering the temperature of the exhaust gas, which is entered to the intake manifold, to
decrease the combustion temperature is more effective way to reduce the NOx content in the
exhaust gas, and this is the main function of the EGR cooler.
The cooler consists of conventional EGR center pipe with cooling circuit added. And the
capacity of the engine water pump is increased to improve the coolant flow.

2) Mounting Location
E-EGR cooler

1. E-EGR cooler
2. EGR cooler gasket
3. Wavy fin

EGR pipe

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3) E-EGR Bypass Valve Overview

Cooling is not necessary before the engine is warmed up because of the low temperature of the
E-EGR cooler. So the bypass valve is open and the EGR gas is supplied directly to the
combustion chamber (bypass). The CO and HC content in the exhaust gas is reduced through
these processes. After the engine is warmed up, the bypass valve is closed and the EGR is
cooled down sufficiently. This causes the low temperature of the combustion chamber which
leads to the reduced NOx content in the exhaust gas.

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4) E-EGR Cooler Assembly Operation

▶ At normal engine operating temperature
When the engine reaches normal operating temperature, the E-EGR bypass valve is closed
and the hot exhaust gas is cooled down when it passes through the U-shaped E-EGR cooler.
The wavy fin is installed inside the E-EGR cooler to maximize the cooling efficiency.

Bypass valve
(OFF status)

▶ When the engine is cold

Bypass valve
(ON status)

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1) E-EGR System

1793

1. Valve assembly - EGR 23.Hose - EGR cooler outlet

3. Bolt 24.Hose - Hot water inlet
5. Pipe assembly - EGR 25.Pipe assembly - Turbocharger cooling inlet
7. Gasket - EGR pipe 26.Gasket - Turbocharger cooling
12.Cooler assembly - EGR 27.Hose - Turbocharger cooling inlet
13.Bolt 29.Bolt
18.Clamp 30.Clamp
19.Gasket - EGR cooler 31.Hose - EGR valve
20.Bolt 32.Clamp
21.Bolt
22.Bolt

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- Disconnect the negative cable from the battery.

- Remove the acoustic cover.
- Remove the air cleaner housing assembly.

1. Unscrew the bolts (A) and bolts (B), and

1
remove the EGR pipe.

- Always replace the gasket with a new

one, because the used one is deformed
by heat and can cause a leak.
- Make sure the installation direction of the
gasket is correct.

2. Install in the reverse of removal.

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- Remove the air cleaner housing assembly. Refer to "Engine Intake System"
section.
- Disconnect the E-EGR pipe. Refer to "1793-05".
- Remove the undercover.

1. Unplug the drain cock at the bottom of the

radiator to drain the coolant completely.

- Never open the cap if the coolant

temperature is more than 90℃
(194℉) to prevent any burn.
- Drain the coolant into a suitable
container and do not spill it on the floor.
- Avoid the coolant to come in contact
with your skin or the vehicle body as
anti-freeze is included. In case of skin
contact, wash thoroughly with plenty of
clean water immediately.
- The coolant to be replaced or added
should be original coolant with the same
specifications.

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2. Disconnect the hose between the

intercooler and the electric throttle valve.

3. Remove the electric throttle valve.

- Disconnect the connector (A).
- Unscrew the bolts (B).

4. Unscrew the bolts (A) and bolts (B), and

remove the EGR pipe.

Replace the gasket with a new one.

(A) Part No. 6711420280
(B) Part No. 6651420180

5. Unscrew the bolts (A) and remove the

intake duct.

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6. Disengage the clamp and disconnect the

E-EGR cooler inlet hose (A).
7. Unscrew the mounting bolts (B) of the
EGR cooler.
8. Unscrew the bolts (C) and remove the
EGR cooler assembly.

Make sure that no coolant leaks.

To disconnect the vacuum hose, insert the

tip of a flat-bladed screwdriver to the
groove on the side of the bypass valve.

9. Install in the reverse order of removal.

E-EGR cooler

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