Exhaust gas recirculation (EGR) - Revision history

Pokseva: /* EGR pressure transducer (Y31/1) */

2017-08-26T17:03:42Z

EGR pressure transducer (Y31/1)

← Older revision		Revision as of 17:03, 26 August 2017
Line 132:		Line 132:
	* No signal from control unit: The connections OUT and ATM are linked. The exhaust gas recirculation valve is close (ventilated).		* No signal from control unit: The connections OUT and ATM are linked. The exhaust gas recirculation valve is close (ventilated).
	* Signal from control unit: The valve unit opens proportional to the current flow in the coil. The vacuum acts partially or fully at connection OUT and operates the ERF valve accordingly.		* Signal from control unit: The valve unit opens proportional to the current flow in the coil. The vacuum acts partially or fully at connection OUT and operates the ERF valve accordingly.

			[[File:W220_EGR_screw.jpg\|thumb\|none\|EGR transducer attachment screw.]]

	== Exhaust gasket ==		== Exhaust gasket ==

Pokseva: /* Fault codes */ added P0403

2017-01-26T10:23:44Z

Fault codes: added P0403

← Older revision		Revision as of 10:23, 26 January 2017
Line 189:		Line 189:
	{\| class="wikitable"		{\| class="wikitable"
	! Error Code		! Error Code
			! Generated By
	! Description		! Description
	\|-		\|-
	\|P0400		\|P2001
	\|~~Exhaust Gas Recirculation Flow Malfunction~~		\|ME-SFI 2.8 - Motor electronics 2.8
			\|Malfunction of exhaust gas recirculation (functional chain) (P0400)
			\|-
			\|P2027-004
			\|ME-SFI 2.8 - Motor electronics 2.8
			\|Y31/1 (EGR vacuum transducer) (P0403)
	\|}		\|}


	Possible causes for EGR malfunction:		Possible causes for EGR malfunction:
Line 201:		Line 208:
	* EGR valve is clogged with carbon (cleaning with carbon spray usually helps).		* EGR valve is clogged with carbon (cleaning with carbon spray usually helps).
	* The membrane in EGR valve is broken resulting in EGR valve being always closed.		* The membrane in EGR valve is broken resulting in EGR valve being always closed.
	* The electrical connection to EGR transducer is broken.		* The electrical connection to EGR transducer (selenoid) is broken. This will produce P0403 code.
	{\|		{\|
	\|{{#ev:youtube\|https://www.youtube.com/watch?v=BLQ8HQBzc74\|320\|left\|Exhaust line clogged with carbon.\|frame}}		\|{{#ev:youtube\|https://www.youtube.com/watch?v=BLQ8HQBzc74\|320\|left\|Exhaust line clogged with carbon.\|frame}}

Pokseva: /* Fault codes */ youtube videos

2016-12-12T19:10:04Z

Fault codes: youtube videos

← Older revision		Revision as of 19:10, 12 December 2016
Line 186:		Line 186:

	== Fault codes ==		== Fault codes ==
	P0400 Exhaust Gas Recirculation Flow Malfunction
			{\| class="wikitable"
			! Error Code
			! Description
			\|-
			\|P0400
			\|Exhaust Gas Recirculation Flow Malfunction
			\|}

			Possible causes for EGR malfunction:
			* The EGR transducer (control selenoid) is faulty and fails open. This will produce P0400 code and will create rough idling.
			* Any of rubber vacuum lines broken. This will result in EGR valve being always closed.
			* Exhaust line clogged with carbon (see the video below).
			* EGR valve is clogged with carbon (cleaning with carbon spray usually helps).
			* The membrane in EGR valve is broken resulting in EGR valve being always closed.
			* The electrical connection to EGR transducer is broken.
			{\|
			\|{{#ev:youtube\|https://www.youtube.com/watch?v=BLQ8HQBzc74\|320\|left\|Exhaust line clogged with carbon.\|frame}}
			\|{{#ev:youtube\|https://www.youtube.com/watch?v=018NzJe9tSY\|320\|left\|Cleaning EGR valve.\|frame}}
			\|{{#ev:youtube\|https://www.youtube.com/watch?v=oxHapwV2F3g\|320\|left\|Broken EGR vacuum hose.\|frame}}
			\|}
			{\|
			\|{{#ev:youtube\|https://www.youtube.com/watch?v=AVC8qBwQlRw\|320\|left\|Understanding and diagnosis of EGR.\|frame}}
			\|{{#ev:youtube\|https://www.youtube.com/watch?v=ud60NZuma-A\|320\|left\|EGR valve function and testing.\|frame}}
			\|}

Pokseva: update with parts

2016-12-12T18:51:38Z

update with parts

← Older revision		Revision as of 18:51, 12 December 2016
Line 16:		Line 16:
	* B11/4 - Coolant temperature sensor		* B11/4 - Coolant temperature sensor
	* B37 - Accelerator pedal sensor		* B37 - Accelerator pedal sensor
	* L5 - Crankshaft position sensor		* L5 - [[Crankshaft position sensor]]
	* M16/6 - Throttle valve actuator		* M16/6 - Throttle valve actuator
	* N3/10 - ME-SFI [ME] control unit		* N3/10 - ME-SFI [ME] control unit
Line 54:		Line 54:
	The inducted air mass is reduced by the quantity of exhaust gases recycled.		The inducted air mass is reduced by the quantity of exhaust gases recycled.
	In line with this, the ME-SFI [ME] control unit meters less fuel.		In line with this, the ME-SFI [ME] control unit meters less fuel.

			== Parts ==
			[[File:B14090000037.980528.png\|thumb\|none\|Parts in [[EPC]] related to EGR.]]

			The exhaust gas recirculation valve (89) is combined with an
			electrical EGR pressure transducer (Y31/1) and has part number A1121400060/A1121400460 (PIERBURG OEM ~80 EUR, OE ~130 EUR).

			[[File:A1121400060_EGR_valve_and_transducer.jpg\|thumb\|none\|EGR valve and transducer (A1121400060).]]

	{\|		{\|
	\|[[File:~~W220_EGR_valce_diagram~~.png]]		\|[[File:W220_EGR_valve_diagram.png]]
	\|		\|
	* 89 - Exhaust gas recirculation valve		* 89 - Exhaust gas recirculation valve
Line 64:		Line 72:
	* c - Air admission		* c - Air admission
	\|}		\|}

			=== Exhaust gas recirculation valve (89) ===

			[[File:W220_EGR_valve.jpg\|thumb\|none\|EGR valve.]]

	{\|		{\|
	\|[[File:~~W220_EGR_valce_diagram_crosscut~~.png]]		\|[[File:W220_EGR_valve_diagram_crosscut.png]]
	\|		\|
	* 89/1 - Compression spring		* 89/1 - Compression spring
Line 75:		Line 87:
	\|}		\|}

			=== EGR pressure transducer (Y31/1) ===
			EGR pressure transducer is also known as EGR control selenoid.

			[[File:W220_EGR_pressure_transducer.jpg\|thumb\|none\|EGR pressure transducer.]]
			<!-- GF14.20-P-3106-01A -->
			<!--
	== Position ==		== Position ==
	~~<!-- GF14.20-P-3106-01A -->~~
	The EGR [ARF] vacuum transducer is mounted behind the right cylinder head.		The EGR [ARF] vacuum transducer is mounted behind the right cylinder head.

	{\|		{\|
	\|[[File:W220_Exhaust_gas_recirculation_vacuum_transducer_position.png]]		\|[[File:W220_Exhaust_gas_recirculation_vacuum_transducer_position.png]]
Line 85:		Line 101:
	* Y31/1 - EGR vacuum transducer		* Y31/1 - EGR vacuum transducer
	\|}		\|}
			-->
	~~== Function ==~~
	<!-- GF14.20-P-3106-02A -->		<!-- GF14.20-P-3106-02A -->
	<!-- GF14.20-P-3106A -->		<!-- GF14.20-P-3106A -->

	{\|		{\|
	\|[[File:W220_Exhaust_gas_recirculation_vacuum_transducer_function.png]]		\|[[File:W220_Exhaust_gas_recirculation_vacuum_transducer_function.png]]
	\|		\|
	* A - Compression spring		* a - Compression spring
	* B - Valve plate with diaphragm		* b - Valve plate with diaphragm
	* c - Housing, pressure regulator		* c - Housing, pressure regulator
	* D - Hose line (guides controlled vacuum of approx. -200 mbar to the electrical unit)		* d - Hose line (guides controlled vacuum of approx. -200 mbar to the electrical unit)
	* e - Coil		* e - Coil
	* F - Electromagnetically operated valve unit		* f - Electromagnetically operated valve unit

	* ATM - Atmospheric pressure, air admission via cylinder head		* ATM - Atmospheric pressure, air admission via cylinder head
Line 118:		Line 132:
	* No signal from control unit: The connections OUT and ATM are linked. The exhaust gas recirculation valve is close (ventilated).		* No signal from control unit: The connections OUT and ATM are linked. The exhaust gas recirculation valve is close (ventilated).
	* Signal from control unit: The valve unit opens proportional to the current flow in the coil. The vacuum acts partially or fully at connection OUT and operates the ERF valve accordingly.		* Signal from control unit: The valve unit opens proportional to the current flow in the coil. The vacuum acts partially or fully at connection OUT and operates the ERF valve accordingly.

			== Exhaust gasket ==
			Gasket for exhaust gas recirculation valve to cylinder head has part number A1121420280 (~2 EUR).
			[[File:A1121420280_EGR_exhaust_gasket.jpg\|thumb\|none\|EGR exhaust gasket.]]

			== Exhaust gas recirculation line (89/1) ==
			Exhaust gas recirculation line has part number A1121400108 (~70 EUR).
			[[File:A1121400108_EGR_exhaust_line.jpg\|thumb\|none\|EGR exhaust line (A1121400108).]]
			Union nut (89/3) is a separate part A0009906854 (~3 EUR).

			The line (89/1) is connected to the intake mainfold with two screws N910143006001.

			The gasket for exhaust gas recirculation line to intake mainfold has part number A1121412180 (~2 EUR).
			[[File:A1121412180_EGR_intake_gasket.jpg\|thumb\|none\|EGR intake gasket.]]

	== Removing exhaust gas recirculation valve ==		== Removing exhaust gas recirculation valve ==
	<!-- AR14.20-P-7662A -->		<!-- AR14.20-P-7662A -->
	{\|		{\|
			\|[[File:W220_EGR_system.jpg]]
	\|		\|
	* 19 - Intake manifold		* 19 - Intake manifold
Line 131:		Line 160:
	* b - Vacuum line		* b - Vacuum line
	* Y31/1 - ARF vacuum transducer		* Y31/1 - ARF vacuum transducer
	~~\|[[File:W220_EGR_system.jpg]]~~
	\|}		\|}

	{\|		{\|
			\|[[File:W220_Exhaust_gas_recirculation_valve.jpg]]
			\|[[File:W220_ARF_vacuum_transducer.jpg]]
	\|		\|
	* 1 - Oil dipstick guide tube		* 1 - Oil dipstick guide tube
Line 142:		Line 172:
	* 89/3 - Union nut		* 89/3 - Union nut
	* Y31/1 - ARF vacuum transducer		* Y31/1 - ARF vacuum transducer
	~~\|[[File:W220_Exhaust_gas_recirculation_valve.jpg]]~~
	~~\|[[File:W220_ARF_vacuum_transducer.jpg]]~~
	\|}		\|}

Pokseva: /* Function */

2016-12-10T19:03:11Z

Function

@@ Line 74: / Line 74: @@
 * 89/5 - Housing
 |}
 == Removing exhaust gas recirculation valve ==

Pokseva: /* Function */

2016-12-10T18:42:20Z

Function

← Older revision		Revision as of 18:42, 10 December 2016
Line 6:		Line 6:

	[[File:EGR_diagram.png\|700px\|none]]		[[File:EGR_diagram.png\|700px\|none]]

			== Function ==
			<!-- GF14.20-P-3000A -->
			{\|
			\|[[File:W220_exhaust_gas_recirculation_function.png]]
			\|
			* 89 - Exhaust gas recirculation valve
			* B2/5 - Hot film mass air flow sensor
			* B11/4 - Coolant temperature sensor
			* B37 - Accelerator pedal sensor
			* L5 - Crankshaft position sensor
			* M16/6 - Throttle valve actuator
			* N3/10 - ME-SFI [ME] control unit
			* Y31/1 - EGR [ARF] vacuum transducer
			* a - Vacuum supply from intake manifold
			* b - Controlled vacuum from EGR [ARF] vacuum transducer to exhaust gas recirculation valve
			\|}

			The exhaust gas recirculation valve (89) is combined with an
			electrical EGR pressure transducer (Y31/1).

			The EGR pressure transducer (Y31/1) stabilizes the sharp vacuum
			fluctuations in the intake, and is actuated by the ME-SFI control
			unit with a PWM signal, which has a frequency of about 10 Hz
			and a duty cycle of about 30 to 100%.

			The EGR valve is actuated with a vacuum of about 80 to 200
			mbar, and is opened to varying widths in order to control the
			quantity of exhaust gases that are recirculated.

			The exhaust gases are recirculated in line with the map stored in
			the ME control unit as soon as the following conditions are met:
			* Coolant temperature between 60°C and 110°C
			* Engine speed <3500 rpm
			* Partial load.

			The performance map is designed to optimize fuel consumption. In
			this case as much exhaust gas as possible is recirculated without
			impairing engine running or exhaust emissions.

			Exhaust gas low in oxygen content is drawn in through the exhaust
			gas recirculation valve, depending on the cross-section of the
			valve opening. Consequently, the fuel-air mixture has a lower
			oxygen concentration. The combustion temperature drops and the
			formation of NO<sub>X</sub> is reduced.

			The inducted air mass is reduced by the quantity of exhaust gases recycled.
			In line with this, the ME-SFI [ME] control unit meters less fuel.

			{\|
			\|[[File:W220_EGR_valce_diagram.png]]
			\|
			* 89 - Exhaust gas recirculation valve
			* Y31/1 - EGR [ARF] vacuum transducer
			* a - Vacuum supply from intake manifold
			* b - Controlled vacuum from EGR [ARF] vacuum transducer to exhaust gas recirculation valve
			* c - Air admission
			\|}

			{\|
			\|[[File:W220_EGR_valce_diagram_crosscut.png]]
			\|
			* 89/1 - Compression spring
			* 89/2 - Vacuum reservoir
			* 89/3 - Diaphragm
			* 89/4 - Valve seat
			* 89/5 - Housing
			\|}

	== Removing exhaust gas recirculation valve ==		== Removing exhaust gas recirculation valve ==

Pokseva: Created page with "== Exhaust Gas Recirculation (EGR) == The Exhaust Gas Recirculation (EGR) system redirects a small portion of exhaust gase..."

2016-12-10T18:10:44Z

Created page with "== Exhaust Gas Recirculation (EGR) ==  The Exhaust Gas Recirculation (EGR) system redirects a small portion of exhaust gase..."

New page

== Exhaust Gas Recirculation (EGR) ==

The Exhaust Gas Recirculation (EGR) system redirects a small portion of exhaust gases from the exhaust manifold back into the intake manifold (see the diagram) to lower the combustion temperature.
The engine computer regulates the flow of the EGR gases by opening or closing the EGR valve. The EGR flow is at its maximum during steady highway cruising.
The engine computer periodically tests the operation of the EGR system. If the engine computer detects that the EGR flow is less or greater than expected, it sets the fault code P0400 - Exhaust Gas Recirculation Flow Malfunction.

[[File:EGR_diagram.png|700px|none]]

== Removing exhaust gas recirculation valve ==

{|
|
* 19 - Intake manifold
* 89 - Exhaust gas recirculation valve
* 89/1 - Exhaust gas recirculation line
* 89/2 - Vacuum reservoir
* 89/3 - Union nut
* a - Vacuum line from intake pipe
* b - Vacuum line
* Y31/1 - ARF vacuum transducer
|[[File:W220_EGR_system.jpg]]
|}

{|
|
* 1 - Oil dipstick guide tube
* 2 - Fuel rail
* 3 - Plug connection
* 89 - Exhaust gas recirculation valve
* 89/3 - Union nut
* Y31/1 - ARF vacuum transducer
|[[File:W220_Exhaust_gas_recirculation_valve.jpg]]
|[[File:W220_ARF_vacuum_transducer.jpg]]
|}

# Remove cover on front side of engine
# Remove air filter housing
# Remove engine cover with integrated air filter
# Unplug connector on EGR pressure transducer (Y31/1).
# Detach vacuum line (b) to vacuum unit (89/2) and EGR pressure transducer (Y31/1)
# Unscrew union nut (89/3) on exhaust gas recirculation valve (89)
# Dismount EGR line (89/1) from intake manifold (19)
# Unscrew exhaust gas recirculation pipe (89) from cylinder head
# Remove exhaust gas recirculation valve (89). Installation: Replace gaskets. Note length and routing of vacuum line from intake manifold to EGR [ARF] vacuum transducer (Y31/1). Incorrect routing may cause throttle lever to jam.
# Install in the reverse order

== Fault codes ==
P0400 Exhaust Gas Recirculation Flow Malfunction