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
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