2013 SSANGYONG TURISMO EGR

03-32210-01
1. SPECIFICATIONS
Description Specification
Fuel Diesel
Fuel filter Type Fuel heater + priming pump + water
separator integrated type
Filter type Changeable filter element type
Change interval EU every 40,000 km
GEN every 45,000 km
Water separation
intervalEU every 20,000 km
GEN every 15,000 km
Water accumulating capacity 200 cc
Heater capacity 250W 13.5V
Injector System pressure 1800 bar
High pressure fuel
pumpType Eccentric cam/Plunger type
Operating type Gear driven type
Normal operating temperature-40 ~ 125˚C
Operating pressure 1800 bar
Operating temperature-30 ~ 120˚C
Low pressure fuel
pumpType Vane type
Gear ratio (pump/engine) 0.5 : 1
Pressure 6 bar
Fuel tank Capacity 80 L
Material Plastic
Fuel sender Single sender type

03-26
The engine ECU calculates the accelerator pedal based on the input signals from various sensors, and
controls the overall operation of the vehicle.
The ECU receives the signals from various sensor through data line, and performs effective air-fuel ratio
control based on these signals.
The crankshaft speed (position) sensor measures the engine speed, and the camshaft speed (position)
sensor determines the order of injections, and the ECU detects the amount of the accelerator pedal
depressed (driver's will) by receiving the electrical signals from the accelerator pedal sensor.
The mass air flow sensor detects the volume of intake air and sends the value to the ECU.
The major function of the ECU is controlling air-fuel ratio to reduce the emission level (EGR valve
control) by detecting instantaneous air flow change with the signals from the mass air flow sensor.
Also, the ECU uses the signals from the coolant temperature & air temperature sensors, booster
pressure sensor, atmospheric pressure sensor to: a) determine injection starting point and set value for
pilot injection, and b) deal with various operations and variable conditions.

04-4
2. INSPECTION
1) Troubleshooting
When Abnormal Noises are Heard from the Engine Room ▶
For the vehicle equipped with DI engine, if a learning noise occurs in each range or other noises
occur, the major cause of it is a faulty turbocharger assembly. But an interference issue, poor
tightness or loose in the intake and exhaust system also can cause those noises. This is mainly
because the operator didn't follow the instruction exactly when reconnecting the intake hoses and
pipes which were disconnected to check the system or replace the air cleaner. If the intake system
is free of any faults, check the EGR and PCV oil separator connected to the intake system.
The figure may be different from the actual engine. Therefore, read thoroughly below before
replacing the parts.
2) Abnormal Noise Caused by Poor Tightness of Intake System
When the DI engine is running, the air entered into the engine flows in the sequence as shown above.
If high intake pressure is applied to the loose or damaged part, a whistling noise may occur, the intake
air volume is measured incorrectly or the engine power is derated.

04-51719-00
3) Troubleshooting Sequence
The basic checks for intake system are as follows:
Basic Checks for Intake System ▶
Make sure to replace or clean the air cleaner
element periodically. Otherwise, engine will be
derated or work abnormally because of low
intake air volume.
Unlike the fuel system, which is a closed
circuit, the intake system is an open circuit
system. Therefore any malfunction may occur
due to dust and dirt.
Most of the connections consist of hoses so the
system cannot withstand high temperature and
pressure. Also it can be deformed or loosened
easily because it is a clamp mounting system.
Thus, when checking the engine, basic
inspections, such as tightened status check and
visual inspection for hose, etc., should be carried
out in advance.
Other Checks for Intake System ▶
If the intake system is free of any faults,
check for EGR and PCV oil separator.

04-10
1) Types of swirl
Swirl: One cylinder has two intake air ports, one is set horizontally and
the other one is set vertically. Swirl is the horizontal air flows in cylinder
due to the horizontal intake air ports.
Tumble: Tumble is the vertical air flows in cylinder due to the vertical
intake air port
Squish: Squish is the air flows due to the piston head. Normally, this is
appears at the final process of compression. In CRDi engine, the
piston head creates the bowl type squish.
2) Swirl control
In DI type diesel engine, the liquefied fuel is injected into the cylinder directly. If the fuel is evenly
distributed in short period, the combustion efficiency could be improved. To get this, there should be
good air flow in cylinder. In general, there are two intake ports, swirl port and tangential port, in each
cylinder. The swirl port generates the horizontal flow and the tangential port generates the longitudinal
flow. In low/mid load range, the tabgential port is closed to increase the horizontal flow. Fast flow
decreases the PM during combustion and increases the EGR ratio by better combustion efficiency.

04-111719-00
LoadEngine
speedSwirl valve Amount of
swirlRemarks
Low speed,
Low loadbelow 3,000
rpmClosed HeavyIncreased EGR ratio, better air-fuel
mixture (reduce exhaust gas)
High speed,
High loadover 3,000
rpmOpen LightIncrease charge efficiency, higher
engine power
The variable swirl valve actuator operates when
turning the ignition switch ON/OFF position to
open/close the swirl valve. In this period, the
soot will be removed and the learning for swirl
valve position is performed.
Swirl: This is the twisted (radial) air flow along the cylinder wall during the intake stroke. This
stabilizes the combustion even in lean air-fuel mixture condition.
Swirl valve
3) Features
Swirl and air intake efficiency
To generate the swirl, the intake port should be serpentine design. This makes the resistance in air
flow. The resistance in air flow in engine high speed decreases the intake efficiency. Eventually, the
engine power is also decreased, Thus, the swirl operation is deactivated in high speed range to
increase the intake efficiency.
Relationship between swirl and EGR
To reduce Nox, it is essential to increase EGR ratio. However, if EGR ratio is too high, the PM also
could be very higher. And, the exhaust gas should be evenly mixed with newly aspired air.
Otherwise, PM and CO are dramatically increased in highly concentrated exhaust gas range and
EGR ratio could not be increased beyond a certain limit. If the swirl valve operates in this moment,
the limit of EGR ratio will be higher. -
-
4) Relationship Between Swirl and Fuel Injection Pressure
The injector for DI engine uses the multi hole design. For this vehicle, there are 8 holes in injector. If the
swirl is too strong, the injection angles might be overlapped and may cause the increased PM and
insufficient engine power. Also, if the injection pressure is too high during strong swirl, the injection
angles might be overlapped. Therefore, the system may decreases the fuel injection pressure when
the swirl is too strong.

10-71413-00
4) Operation
Glow plug is installed in the cylinder head. It enhances the cold starting performance and reduces the
exhaust gas during cold starting.
ECU receives the data (engine rpm, coolant temperature, vehicle speed) through CAN lines. Based on
the data, GCU controls the pre-glow, cranking and post-glow. It also checks the glow plugs, and sends
the result to ECU.
(1) Temperature/Current Properties of GCU
GCU increases the temperature of glow plug very rapidly (approx. 2 seconds up to
1000°C)
FETs (similar to transistor) for each cylinder are integrated in GCU. During the pre-glow
period, battery voltage is supplied to the glow plugs directly to heat them rapidly.
After getting the desired temperature by pre-glowing, the temperature is controlled by duty
ratio. Step 1:
Step 2 & 3:
Step 4:
This shows the supplying voltage and time by GCU in each step. The step 4 is the period to keep
the temperature. -Step 1: I1
Step 2: I2
Step 3: I3
Step 4: I4

13-31793-00
1. SPECIFICATION
Item Specification
E-EGR valve Motor EGR response time 50 ms
Driven by DC motor
Valve EGR gas flow rate 120 Kg/h
Position sensor Sensing type Hole sensor
Supplied voltage5V ± 10%
Maximum signal
range5% ~ 95%
Maximum power
consumption＜15mA
E-EGR cooler Cooling capacity 8.3 kW or more
Cooling fin type Wavy fin
Cooler type U-shaped
E-EGR bypass valve Driven by Vacuum
(Solenoid valve)