SsangYong Stavic / SsangYong Rodius (2005 year). Manual - part 106

DI04-17

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

EXHAUST SYSTEM

DI ENG SM - 2004.9

Before Diagnosis

The base of making diagnosis on the EGR related system is the inspection on the connections of the vacuum hoses in
related system as the first priority. When abnormal condition occurs with the EGR system, the basic approach is, as
described in prior sentence, making detail inspections of vacuum circuits of each system before connecting the scan
tool or vacuum tester. It is necessary to manually check on the connections if there are any slacks or loose circuits even
if the visual inspection shows vacuum hose as being connected. If there are not any problems then the next inspection
area is the connections of the system connectors. Most problems with the occurrence of system malfunction are from
conditions of vacuum line and connector connections and the causes from the malfunction of mechanical mechanism is
actually very few.

For example, when there are no problems with basic components, let’s assume that there is a vehicle having vacuum
leak from connection slack in the vacuum line between EGR vacuum modulator and EGR valve. This vehicle, due to the
driving condition or, according to the circumstances, smog or other conditions, could create customer’s complaint and
by connecting the scanning device could display as the malfunction of the EGR valve’s potentiometer.

As previously explained, this car has a separate controller to control the HUBER EGR and, in accordance with various
input element, the controller controls EGR valve by regulating the force of vacuum being applied to the EGR valve through
PWM control. At this time, the controller has to receive feedback whether the EGR valve operates correctly according to
the value sent to the EGR modulator and this role is performed by the EGR potentiometer located at top section of the
EGR valve.

In other word, the controller sent correct output value to the EGR vacuum modulator but, due to the leakage of vacuum,
signal of required value can not be received from the EGR potentiometer causing to display as malfunction of related
parts.

As a reference, the EGR valve of diesel vehicle (DI Engine) controlling from the engine ECU to EGR system has different
shape than the HUBER EGR valve because the EGR valve’s operation signal in the DI engine is performed by the HFM
sensor instead of the EGR potentiometer.

This principle is that when the EGR valve opens up to flow exhaust gas into the intake unit the amount of fresh air,
comparatively, will be reduced. The DI engine ECU receives feedback signal of change in amount of air being passed
through the HFM sensor according to the opening amount of the EGR valve.

HUBER EGR System for IDI Engine

(Including the EGR Valve Potentiometer)

EGR System for DI Engine

DI04-18

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

EXHAUST SYSTEM

DI ENG SM - 2004.9

The other big difference between the HUBER EGR and EGR controller for DI engine is that from two vacuum modulator,
one is same as being the modulator for EGR valve whereas the HUBER EGR system’s the other modulator controls
ALDA of injection pump and the DI engine’s the other modulator controls waist gate of the turbo charger.

This difference is in accordance with the difference in fuel injection method where the IDI engine has mechanical
injection system and DI engine is capable of making electronically controlled fuel injection.

In other word, to reduce the amount of the fuel injection in no-load rapid acceleration mode, the IDI engine’s HUBER
EGR utilizes solenoid valve to disconnect the connection circuit between intake manifold and ALDA causing negative
pressure to occur in the vacuum modulator to reduce the amount of fuel injection. When DI engine, basing input signal
from the related sensors such as acceleration pedal sensor and engine RPM, recognizes that current mode is the no-
load rapid acceleration mode it reduces the amount of fuel injection by sending short electrical signal to the injector.
Therefore, disregarding the modulator for the EGR valve in DI engine, one must keep in mind that the other modulator is
used to control the booster pressure valve in turbo charger.

DI04-19

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

EXHAUST SYSTEM

DI ENG SM - 2004.9

When Engine Exhaust Gas shows White Smog or

Blue Smog

Poor Connection between

Compressor Outlet and

Intake Manifold

Oil Leak Sign around

Intake Manifold

Clogging of Engine Oil

Element

NO

NO

YES

YES

YES

Reconnection

Inspect PVC Line

Replace Oil Filter

NO

Clogging or Damage

between Air Cleaner and

Turbo

Oil Leakage at Seal

between Turbo Charger

and Compressor

Engine Malfunction (Ring,

Piston, Valve)

NO

NO

YES

YES

Clean or Replace Affected

Components

Repair (overhaul)

Engine

Improper Inspection of Air

Cleaner Contamination

Improper Viscosity of

Engine Oil Being Used

Poor Oil Seal at Turbo

Compressor Side (Oil leak

sign at housing and wheel)

NO

NO

YES

YES

YES

Replace Air Cleaner

Element

Replace with Specified Oil

Refer to Diagnosis

Table

NO

Poor Oil Seal at Turbo Turbine

Side (trace of leakage in

housing and wheel)

Oil Leakage at Engine

Exhaust Manifold (damages

to ring, piston and valve)

NO

YES

Refer to Diagnosis Table

YES

Inspect or repair Manifold

YES

Refer to Diagnosis Table

Excessive Consumption of Engine Oil

DI04-20

CHANGED BY

EFFECTIVE DATE

AFFECTED VIN

EXHAUST SYSTEM

DI ENG SM - 2004.9

Abnormal Noise from Turbo Charger System

Contamination or Clogging

of Air Cleaner

Leaks at Pipe and Hose

Duct Parts between

Manifolds of Turbo Charger

Inflow of Foreign Material

to Compressor Entrance

or Housing

YES

YES

YES

Clean or Replace If

required

Inspect or Replace

Connections

NO

Inflow of Foreign Materials

to Intake Manifold

Inflow of Foreign Materials

to Muffler

Poor Rotation of Rotating

Turbo Charger Compo-

nents and Interference

YES

YES

Inspect and Repair Air

Cleaner Element and Turbo

Charger after Removing

Foreign Materials

Repair Housing and

Turbo Charger and

Inspect Normal Opera-

tion for Engine

NO

Check the Interference

between Rotating Turbo

Charger Components and

Housing

YES

Refer to Diagnosis Table

Inspect and Repair Air

Cleaner Element and Turbo

Charger after Removing

Foreign Materials

YES

Repair Muffler and Turbo

Charger After Removing

Foreign Materials

NO

NO

NO

NO