42

04

EGR VALVE AND TURBO CHARGER ACTUATOR CONTROL VACUUM

CIRCUIT
Vacuum Modulator
The biggest difference between the vacuum circuit and layout of the HUBER EGR system after K2004 has been
introduced is the location of the vacuum modulator for EGR valve control and the function of the other modulator. In
case of EGR equipped vehicle (IDI Engine), it performs the role of controlling the PLA of injection pump whereas, in
DI engine, it controls the turbo charger actuator.

DI engine vacuum modulator

1. Turbo charger booster vacuum modulator

D20DT
To EGR valve

From vacuum pump

2. EGR valve vacuum modulator

To Turbo Charger Actuator (Gray)

To EGR Valve (Black)

To turbo charger
actuator

Vacuum pump

D27DT

From vacuum
pump
To EGR Valve

To turbo charger
actuator

Vacuum pump

1. Vacuum modulator for EGR valve control

2. Vacuum modulator for injection pump PLA control

EXHAUST SYSTEM
KYRON SM - 2005.09

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Vacuum Modulator and Vacuum Hose

Below figures illustrate vacuum hoses and related parts of EGR or turbo where wrong or poor connection of vacuum
hose would display condition of engine irregularity and defect diagnostic codes on the scan tool.

ASSY

Related with EGR valve

GENERAL

04

HOUSING

From vacuum pump

COOLING

LUB

EXHAUST I N T A K E

EGR valve

FUEL

Vacuum modulator for

EGR valve control

SENSOR

CONTROL

Related with turbo charger actuator

Turbo charger pressure valve

Vacuum modulator for turbo

charger booster control

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From vacuum pump

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KYRON SM - 2005.09

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04

EGR System Diagram

Intercooler

Exhaust
manifold

Intake
manifold
EGR
valve
Regulated
vacuum
pressure

Modulator

Vacuum
pump

Duty
control

Feedback EGR
(Air Mass)
ECU
Improved target EGR

Air intake
signal (for
EGR feedback
control)
Turbo charger

Pedal RPM
signal signal

EGR valve
EGR valve recirculates some of exhaust gases to intake system to reduce toxic NOx from engine according to ECU
signals.
1. EGR valve opening point : -270 mmHg

EGR modulator
According to ECU signals, the vacuum modulator drives EGR valve by controlling vacuum pressure that is generated
by vacuum pump with PWM type controls.

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KYRON SM - 2005.09

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GENERAL

Operation Principle of Vacuum Modulator

ASSY

Vacuum
pump

HOUSING

Output vacuum

ATM

EXHAUST I N T A K E

Plunger

COOLING

LUB

Connector

Vacuum
control

FUEL

Diaphragm
Seat assembly
Spring

Atmospheric pressure

SENSOR

CONTROL

Plunger

Air flow

During duty increase (B)

During duty reduction (C)

Vacuum is controlled according to relationship between chamber pressure (I) in rolling nipple cover
and magnetic force (II) in plunger.

According to ECU signals, the solenoid valve controls the vacuum pressure that is generated by vacuum pump (-900
20 mbar) with PWM type control and drives the mechanical EGR valve and turbo charger.
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04

Operating principle: Balance between original vacuum pressure and magnetic forcs (see aboe figure)
1. Normal state (Fig. A): Original vacuum and seat section, 3 stoppers keep sealing
2. Duty up state (Fig. B): Original vacuum pressure is connected to inside of diaphragm chamber
3. Duty down state (Fig. C): Increased diaphragm chamber pressure is connected to atmosphere to compensate
the pressure.
Floating plunger

DUTY 50%

Stroke
(mm)
Max. Distance
1mm

Output C/V

Operating principles when duty is applied from 0 to 50 %

Vacuum consumption: Compared to 50 % of duty, ON/OFF periods are most unstable and
vacuum consumption is most high.

Flowing
volume

Output vacuum (-mmHg)

Output characteristics

EXHAUST SYSTEM
KYRON SM - 2005.09

Up
Down

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1. Engine is running
2. Engine RPM is within a specified range. (EGR OFF under high RPM range)
3. Engine torque is within a specified range. (EGR OFF under high torque range)
4. Vehicle speed is within a specified range. (EGR OFF under high speed range)
5. Atmospheric pressure is within a specified range. (EGR OFF under high altitude and low atmospheric pressure)

HOUSING

6. Coolant temperature is within a specified range. (EGR OFF under high or low temperature)

ASSY

GENERAL

Operating conditions

EXHAUST I N T A K E

7. EGR OFF under extended period of idling.

Control logic
1. Main map: EGR volume is controlled based on intake air volume
2. Auxiliary map
1) Coolant temperature (Coolant temperature sensor)
2) Engine rpm (Crankshaft position sensor)
3) Engine load (TPS): Detection of sharp acceleration
5) Atmospheric pressure (Barometric sensor): Compensation of altitude
3. Compensation value of auxiliary map will be increased/decreased based on main map then ECU calculates EGR
volume finally to regulate the vacuum duty that applies to the vacuum modulator to control EGR valve openings.

FUEL

Shut-off conditions

COOLING

LUB

4) Intake air temperature (HFM): Decreases when over 60C

1. Engine rpm: over 2,950 rpm

2. Vehicle speed: over 105 km/h

CONTROL

3. Coolant temperature: over 100C or below 10C

SENSOR

4. Idle period: over 50 seconds

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04

EGR Valve and Pipe

- Removal and Installation
1. Remove the vacuum hose from the EGR valve.
D20DT

D27DT

2. Unscrew the bolts and remove the EGR valve (2), EGR
valve #1 pipe (1) and gasket.
Installation Notice
Tightening torque

25 2.5 Nm

D20DT

D27DT

M6 Bolt: 10 1.0 Nm

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49
GENERAL

3. Remove the EGR valve #1 pipe, #2 pipe, #3 pipe and

gaskets from the engine.
Installation Notice
25 2.5 Nm
D27DT

EXHAUST I N T A K E

HOUSING

D20DT

ASSY

Tightening torque

LUB

4. Install in the reverse order of removal.

COOLING

NOTICE
Make sure to observe the specified tightening
torques.
Never reuse the EGR #1 pipe (intake) and #3 pipe
(exhaust) once removed (only D27DT).

D27DT
EGR #3 pipe (RH)
EGR #3 pipe (RH)
EGR #1 pipe (LH)

EGR center pipe

SENSOR

EGR center pipe

CONTROL

D20DT

FUEL

Replace the gaskets with new ones.

EGR #1 pipe (LH)

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04

Vacuum Modulator
- Removal and Installation
1. Remove the vacuum hose from the vacuum modulator.
D20DT

D27DT

2. Remove the vacuum modulator from the bracket.

Installation Notice
Tightening torque

10 1.0 Nm

3. Install in the reverse order of removal.

NOTICE
Make sure that the vacuum hoses are connected
to correct locations.

D20DT

EXHAUST SYSTEM
KYRON SM - 2005.09

D27DT

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