Service Bulletin Trucks: Exhaust Gas Recirculation System
Service Bulletin Trucks: Exhaust Gas Recirculation System
Service Bulletin Trucks: Exhaust Gas Recirculation System
W2004292
This information covers design and function of the Exhaust Gas Recirculation System
on the VOLVO D12D engine.
Contents
• “Exhaust Gas Recirculation System” page 2
• “Overview” page 2
• “Pulse EGR” page 3
• “System Components” page 3
• “System Protection” page 6
PV776-TSP194361 USA14006
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 10.2003 254 02 2(6)
Overview
W2004318
A EGR valves
A portion of the exhaust gas is redirected by two EGR
B EGR cooler valves (A) from the exhaust manifold into the EGR cooler
(B). At the end of the EGR cooler are reed valves (C)
C Reed valves
that function as “check valves” to prevent intake air from
D Mixing chamber flowing backwards into the EGR cooler.
E Charge air cooler Cooled EGR gases flow into the mixing chamber (D),
where they mix with intake air that has been cooled
F Intake Manifold
through the charge air cooler (E). From the mixing
G Exhaust gases from exhaust manifold chamber, the combined EGR gases and intake air flow
into the intake manifold (F).
H Main exhaust (EPG housing)
I Charge air The amount of recirculated EGR gases is controlled by
the EGR valves and depends on engine RPM, engine
J Air inlet load, and coolant temperature. Maximum EGR flow is
used under high engine loads.
K Cooled EGR gases
L Cooled charge air
M Charge air/exhaust gas mixture
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 10.2003 254 02 3(6)
Pulse EGR
W2003776
A Exhaust pressure
B Intake pressure
C Pressure differential
System Components
EGR Cooler
The EGR cooler is cooled by engine coolant and contains
a series of internal pipes with vanes that allow the EGR
gases to cool before they reach the mixing chamber.
These vanes cause the gases to swirl, creating a higher
cooling efficiency while reducing deposits.
T2019481
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 10.2003 254 02 4(6)
EGR Valves
The engine uses two EGR valves to control the amount of
gases being recirculated. These valves are cooled by the
engine coolant.
Reed Valves
The reed valves function as check valves to prevent
intake air from flowing backwards into the EGR cooler or
exhaust manifold. They are positioned at the "cool" end of
the EGR cooler to protect them from direct exposure to
the higher temperatures found at the exhaust manifold.
T2019482
Temperature Sensor
A temperature sensor is mounted in the reed valve
housing and is monitored by the engine ECU (EECU). If a
reed valve malfunctions and allows the cooler intake air
to flow into the EGR cooler, the cooler temperature will
result in a fault code being set by the EECU.
W2004307
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 10.2003 254 02 5(6)
System Protection
Condensation
Engine corrosion can occur if exhaust gases are allowed
to condense in the intake manifold. Corrosive substances
can accompany the intake air and cause damage to intake
valves and seats, piston rings, and cylinder liners. This
means that the EGR valves are closed when the coolant
temperature in the cylinder head is below 65 C (149 F).
Diagnostics
The EECU receives information on the exact position of
the EGR valves from the position sensor for each valve.
This, in combination with monitoring for abnormally high
current consumption by EGR valves will detect jammed
valves. If a valve is jammed (or the valve position does
not change), fault codes are set by the EECU.