Exhaust gas recirculation

Fundamentals of exhaust gas recirculation

In order to meet the required emissions standard, it was necessary to introduce an
exhaust gas recirculation system to the heavy truck models as well.

Base function
Because the exhaust gas recirculation (EGR) is active across the entire engine
speed range, the ratio of the recalculated exhaust quantity to the drawn in or
supercharged fresh air quantity must be precisely controlled at all times. With a
combustion mixture with an exhaust portion that is too high, the combustion becomes
worse. The emission of soot particles, carbon monoxide (CO) and hydrocarbons
(HC) increases. Conversely, the emission of nitrogen oxides (NOX) increases if the
portion of fresh or supercharged air is too high.

Exhaust gas recirculation on engine OM471

The new engines of model series OM47x are equipped with an exhaust gas
recirculation (EGR) system. This can reduce the production of nitrogen oxides during
in-engine combustion.

A4 Engine management control unit (MCM)

B621 Exhaust gas recirculation (AGR) differential pressure sensor
B608 Charge air pressure and temperature sensor in charge air pipe
Y621 Exhaust gas recirculation controller
B617 Charge air temperature sensor in charge air distributor

Function
The ratio of the recalculated exhaust quantity to the fresh air quantity is called the
exhaust gas recirculation rate (EGR rate). It is determined by the engine
management (MCM) control unit (A4). To do so, it forms a ratio of the mass of the
drawn in or supercharged fresh air and the mass of the recalculated exhaust.
The AGR rate is regulated by the exhaust gas recirculation controller. This opens and
closes the throttle valve in the exhaust gas recirculation line via the control lever and
thus controls the exhaust quantity to be added. Only exhaust from cylinders 1 - 3 is
used here. The exhaust to be recalculated flows through the exhaust gas
recirculation cooler connected to the coolant circuit and is cooled from approx. 650
°C to approx. 170 °C in the process. In the charge air pipe, the exhaust is mixed with
fresh air that comes from the charge air cooler and delivered to the individual
cylinders.
The goal of the cooling is to increase the AGR rate, which leads to a reduction of the
combustion temperature and thus to a reduction of the formation of nitrogen oxide.

Design

1 Exhaust gas recirculation cooler

4 Throttle valve
5 Coolant line
6 Coolant line 7 Actuator rod
8 Lever
9 Electrical line
10 Control lever
Y621 Exhaust gas recirculation controller

The exhaust gas recirculation controller (Y621) contains an actuator motor with
adjustment lever, which is connected to a throttle valve in the exhaust gas
recirculation pipe. The exhaust gas recirculation controller is integrated into the
coolant circuit by two lines.

Control of the exhaust gas recirculation rate

The exhaust gas recirculation controller (Y621) is actuated by the engine
management (MCM) control unit via a CAN signal.
When the exhaust gas recirculation controller (Y621) is actuated, it gradually opens
the throttle valve in the exhaust gas recirculation pipe with an actuator rod in order to
control the amount of exhaust which can reach the exhaust gas recirculation cooler.

Exhaust gas recirculation cooler

The exhaust gas recirculation cooler is installed on the right-hand side of the engine.
Coolant flows through it, which allows the flowing exhaust to be cooled down from a
temperature of approx. 650 °C to a temperature of approx. 170°C.
3 Exhaust gas recirculation cooler
4 Exhaust chamber
5 Coolant strip
6 Coolant outlet (to nozzle unit for diesel particulate filter regeneration)
7 Coolant inlet (from nozzle unit for diesel particulate filter regeneration)
8 Coolant outlet
9 Exhaust outlet
10 Coolant inlet (from coolant pump)
11 Exhaust inlet
12 Front end cover
13 Rear end cover
14 Coolant outlet

Exhaust gas recirculation differential pressure sensor (B621)

The “exhaust gas recirculation differential pressure sensor”(B621) is installed at the
exhaust gas recirculation pipe at the front side of the engine and sends the engine
management (MCM) control unit (A4) the information for calculating the EGR rate.
3 Electrical connection
4 High-pressure connection
5 Low-pressure connection
6 Seals
7 Screws

The “exhaust gas recirculation differential pressure sensor” (B621) comprises a

plastic housing that has two chambers on the inside. Both chambers are separated
by a thin membrane that functions as a mechanical intermediate stage.
Four strain gauges (DMS) in the bridge circuit are located on the membrane. The
membrane is exposed to the exhaust on one side and to the intake or charge air on
the other side.
The “exhaust gas recirculation differential pressure sensor” (EGR) (B621) is supplied
with power by the engine management (MCM) control unit. The power supply is
required so that the electronic analysis system can evaluate the pressure differential
via the integrated bridge circuit and transfer this to the engine management (MCM)
control unit (A4).
Function
If exhaust flows through the exhaust gas recirculation pipe, a certain pressure is
applied at the membrane. Due to the pressure, the membrane is deformed and the
strain gauges are elongated or compressed. In accordance with the deformation, the
strain gauges change their electrical resistance. The change in resistance leads to a
change in voltage. Due to this voltage drop, the engine management (MCM) control
unit (A4) can determine the pressure value in the exhaust gas recirculation pipe.