SsangYong: Engine Euro 4. Service manual - part 21

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

9

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

5. REMOVAL AND INSTALLATION E-EGR VALVE ASSEMBLY

Removal and Installation

Ú

Ú

Ú

Ú

Ú Preceding Works: 1. Remove the PCV oil separator hose 

 and the intake inlet duct 

.

2. Drain the coolant.

1. Open the drain cock under the radiator and drain the

coolant completely.

2. Disconnect the coolant inlet hose of EGR cooler pipe.

Coolant inlet hose

1. Oil separator hose

2. Intake inlet duct

EGR cooler

E-EGR valve

EGR cooler coolant
inlet hose

• When removing the E-EGR valve, the EGR cooler pipe should be removed too.

• The solenoid and the valve housing can be separated. However, E-EGR valve assembly should be removed as

a unit for setting the valve seat.

NOTICE

• The coolant should be stored in the designated

container. Be careful not to spill the coolant at any
place.

NOTICE

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

10

1792

EXHAUST SYSTEM

D27DTP/D27DT (EU4)  SM - 2006.08

D27DTP/D27DT (EU4)

3. Disconnect the E-EGR valve connector.

Connector

4. Unscrew the mounting bolts on E-EGR valve and EGR cooler.

EGR No.2 pipe side

EGR pipe

EGR cooler

5. Release the hose clamp and remove the E-EGR valve and EGR cooler.

EGR cooler pipe

EGR pipe

5V

Engine ECU

Ground (-)

Potentiometer

Power (+) (Battery)

E-EGR valve

EGR No.1 pipe side

EGR cooler outlet hose

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

11

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

6. Remove the E-EGR valve and EGR cooler from the

removed E-EGR valve assembly.

7. Separate the valve body and the E-EGR valve coil housing from the E-EGR valve assembly.

Structure of EGR Assembly

EGR pipe

EGR cooler

Throttle body

Intake manifold

EGR cooler

E-EGR valve

Coolant outlet port

E-EGR valve should be
separated after remov-
ing the EGR cooler and
E-EGR valve as a set.

EGR gas inlet hole

EGR pipe

E-EGR valve assembly

Mounting bolts

E-EGR valve coil housing

Valve body

Gasket

Structure of E-EGR Valve

These should be replaced as a unit.

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

12

1792

EXHAUST SYSTEM

D27DTP/D27DT (EU4)  SM - 2006.08

D27DTP/D27DT (EU4)

Exhaust

g a s

Coolant

A

A'

1. OVERVIEW OF EGR COOLER

For D27DTP (POWER UP) engine, the EGR gas gets into intake manifold passing through the EGR cooler.

The EGR system is to reduce the nitrogen oxide (NOx). With the E-EGR valve, the EGR rate can be precisely
controlled as the opening level of valve is precisely controlled and the feedback signal is sent to ECU.

However, for more efficient EGR system (reducing NOx), the temperature of recirculated gas should be decreased.
The EGR cooler decreases this temperature.

The EGR cooler is an additional cooling circuit on the center pipe. Also, the capacity of water pump has been
increased for improving coolant flow.

EGR COOLER

Location

EGR pipe

Exhaust manifold

EGR pipe

E-EGR valve

Coolant port

Coolant flow

EGR gas flow

Intake manifold

(EGR gas passage)

EGR cooler

EGR Cooler

Sectional View of EGR  Cooler: A - A'

EGR gas passage

Coolant passage

2. REMOVAL AND INSTALLATION OF ERG COOLER

* Refer to “E-EGR valve”