EGR

Exhaust GAS Recirculation

 Contents
I Concept

II Major Components

III Working Principle

IV Benefits

V Service Info

VI Troubleshooting

VII FAQ

VIII Parts Info

2 9/5/2015 Service
 Concept

• Exhaust Gas Recirculation is an efficient method to reduce

NOx emissions from the engine.
• It works by Cooling & Recirculating a quantity of exhaust
gas back to the engine cylinders.
• Recirculation is usually achieved by piping a portion of
Exhaust gas from the exhaust manifold to the intake
manifold.
• A control valve within the circuit regulates the gas flow

Q
Major Working Trouble
Concept
3 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Major components

• EGR subassembly
– EGR cooler assembly
– EGR valve assembly
– Exhaust pipes
• Hot pipe from exhaust manifold
• Cold pipe to intake manifold
– Coolant pipes
• Coolant supply pipe from cylinder block
• Coolant return pipe to thermostat housing
– Wiring harness
Major Working Trouble
Concept
4 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Major components – H6 engine
Return Coolant Pipe

Exhaust
Hot
Pipe

EGR Electric Valve

Exhaust Cold Pipe EGR Cooler

Assembly

Inlet Coolant Pipe

Major Working Trouble

Concept
5 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR Cooler & EGR Valve subassy

Coolant IN

EGR Electric Valve

Cooled Coolant
Exhaust out Coolant
Gas OUT out

EGR Cooler Assembly

Hot Exhaust Gas

IN

Q
Major Working Trouble
Concept
6 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR Cooler

Coolant out

Hot Exhaust Gas

IN – Regulated

Cooled Exhaust
Gas OUT Parameter Dimensions
Coolant IN • 36 (4 X 9)
No of tubes
• 255mm length
Weight 2.8kg
Flow type Counter flow

Major Working Trouble

Concept
7 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR Valve
Coolant out

 Electrically actuated EGR

valve
Coolant  DC Electric motor
(From cooler)  Hot side EGR valve
 Engine ECU controlled
Exhaust Gas  Valve operation
(Regulated)  100% - 6 mm
 Common for H4 & H6
Coolant
(From cooler)
Parameter Value
Flow 120kg/hr @ 100dP
Valve dia 30mm
Weight 1.48kg
Major Working Trouble
Concept
8 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Exhaust pipes

Exhaust first pipe from

EMF

Exhaust cooled pipe

Exhaust second pipe to EGR valve

Major Working Trouble

Concept
9 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Coolant pipes

Coolant inlet pipe

(Single pipe)

Coolant Outlet pipe

Major Working Trouble

Concept
10 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR on Engine

Coolant
outlet

EGR Valve
Q Coolant inlet EGR Cooler
Major Working Trouble
Concept
11 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR on Engine

EGR Inlet pipe

Coolant
Supply pipe

Major Working Trouble

Concept
12 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Q
Schematic Diagram
Fuel Coolant
X X ECU Controlled
Exhaust Gas

Injectors
1
Rail

ENGINE ECU actuated Electrically

X
controlled (DC Motor)

Exhaust
Poppet type EGR Valve
CB18 CRS FIP
Inlet

1
COOLANT PIPES
X

EDC 17
X

EGR Valve
EGR Cooler
EATs – DOC

Major Working Trouble

Concept
13 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR – Working principle

• Exhaust gas recirculation (EGR) is an emission control system that

lowers the amount of nitrogen oxides (NOX) formed during
combustion.
• Condition: Engine rpm above 1400 and Coolant temperature
Q exceeds 60°C
Major Working Trouble
Concept
14 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR – Working principle
Peak combustion
temperature

Controlled Combustion
Temperature (for BS IV)

M
With effect of EGR

Major Working Trouble

Concept
15 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR – Working principle

• NOx Formation:
– During combustion, Nitrogen N2 and oxygen O2
molecules are gets reacted and form oxides of
Nitrogen (NOx) at combustion temperature.

• Controlling NOX:
– Exhaust gas from Exhaust Manifold gets cooled
using EGR assembly.
– Redirect back to inlet manifold followed by
combustion chamber and control the combustion
temperature.
Q
Major Working Trouble
Concept
16 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Exhaust After Treatment System

DOC Functional Overview:

• Oxidizes HC & CO
• Residual amount of Oxides of Nitrogen (NOx) getting
converted to NO2.
CO2
H2O
PM (NVF)
NO2

CO
HC
PM (SOF+NVF)
NOx

Major Working Trouble

Concept
17 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Benefits

– Actuates & control through electric valve,

hence expects more reliability with respect
to pneumatic control
– Modular service component easy to
service.
– Compact in size.

Q
Major Working Trouble
Concept
18 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Maintenance & Setting

• Maintenance and Setting free

• Fit and forget concept

Major Working Trouble

Concept
19 Service Benefits Service Info FAQ’s
Components Principle Shooting
 EGR Error codes
P-Codes Description in Diagnostic tools
P0401 Permanent positive governor deviation for valve
P0402 Permanent negative governor deviation for valve
P1206 Jammed valve in closed position
P1205 Jammed valve in open position
P1211 DFC for long time valve drift at closed position
P1212 DFC for long time valve drift at open position
P0406 DFC for valve position sensor voltage SRC high
P0405 DFC for valve position sensor voltage SRC low
P2142 Short circuit to battery at Out1 / Out2
P2141 Short circuit to ground at Out1 / Out2
P0487 Open load error
Fault code for temporary errors
Current limited for H-bridge
TBP
Temperature dependent overcurrent
(To be
Over temperature
provided)
Under voltage
Q Short circuit over load error
Major Working Trouble
Concept
20 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Trouble shooting

• EGR valve WH related issues / Diagnosis

Valve Pin ECU Pin Inter connector Remarks
1 A19 52 DC Motor +ve
2 A12 54 Sensor signal
4 A40 55 Sensor GND
5 A20 53 DC Motor –ve
6 A22 56 Sensor +5V

EGR Cooler Valve connector

Major Working Trouble

Concept
21 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Trouble shooting

• Scan tool version - 2.43

Fault code Description MIL activation Torque Activation criteria
criteria
P0401 EGR valve position governor MIL Immediately No torque limitation
deviation max

P0402 EGR valve position governor MIL Immediately No torque limitation

deviation min

P0401 EGR valve jammed at closed MIL Immediately No torque limitation

position
P0402 EGR valve jammed at open MIL Immediately No torque limitation
position

Major Working Trouble

Concept
22 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Trouble shooting

Fault code Description MIL activation Torque Activation criteria

criteria

P2142 Short circuit to battery at Out1 MIL Immediately No torque limitation

P2142 Short circuit to battery at Out2 MIL Immediately No torque limitation

P2141 Short circuit to ground at Out1 MIL Immediately No torque limitation

P2141 Short circuit to ground at Out2 MIL Immediately No torque limitation

P0487 NO Load Error MIL Immediately No torque limitation

Major Working Trouble

Concept
23 Service Benefits Service Info FAQ’s
Components Principle Shooting
 Trouble shooting
Fault code Description MIL activation criteria Torque Activation
criteria

P0405 SRC low - sensor voltage MIL Immediately After 50hrs 40 %

for EGR valve position torque reduction
sensor

P0406 SRC high - sensor voltage MIL Immediately After 50hrs 40 %

for EGR valve position torque reduction
sensor

Major Working Trouble

Concept
24 Service Benefits Service Info FAQ’s
Components Principle Shooting
 FAQ
• What is EGR?
– Exhaust Gas Recirculation
• Why EGR?
– More reliable, No Maintenance, No
additional fluid requirement.
• Reactions on engine when the EGR electric
valve failed / Malfunction?
– 40% torque reduction if the EGR valve
malfunction above 50Hour
• Maintenance for EGR system?
– No maintenance required.
Major Working Trouble
Concept
25 Service Benefits Service Info FAQ’s
Components Principle Shooting
 FAQ

• Maintenance interval for Engine oil

replacement?
– Oil change period remains same…

Major Working Trouble

Concept
26 Service Benefits Service Info FAQ’s
Components Principle Shooting