Service Bulletin

Volvo Trucks North America, Inc.

Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 254–02, “EGR System
Design and Function, D12D” (11.2002), publication no. 10.2003 254 02 1(6)
PV776–TSP170608.
EGR System
Design and Function
D12D
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

Note: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.

PV776-TSP194361 USA14006
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 10.2003 254 02 2(6)

Design and Function

Exhaust Gas Recirculation System
The Exhaust Gas Recirculation (EGR) System is
designed to recirculate exhaust gases to reduce nitrogen
oxide (NOx) emissions.

NOx content increases with combustion temperature.

Recirculating cooled EGR gases reduces combustion
temperature and, in turn, lowers the level of NOx
emissions.

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

The system uses “Pulse EGR,” meaning that the flow of

EGR gases is controlled by the system using exhaust
pulses that are created at the opening of the exhaust
valves.

The exhaust pulse (A) creates a higher pressure on the

exhaust side than on the intake side (B). This pressure
differential (C) forces the reed valves after the EGR
cooler to open, allowing cooled exhaust gases to enter
the mixing chamber. The pulses from cylinders 1 — 3 are
kept separate from those produced by cylinders 4— 6
until after the reed valve to ensure the pulses don’t cancel
each other out.

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.

Each EGR valve contains a disc valve that is controlled by

an electric motor. Each valve also has a position sensor
to indicate its precise position.
The EGR valves are located on the exhaust manifold
for reliable response and to maintain good turbocharger
efficiency. Their location also protects the EGR cooler
from exhaust pulses at high pressure, e.g. during engine
braking.

EGR valve 1 is the front valve on the exhaust manifold.

It connects to the upper 7–pin connector on the wiring
harness box. EGR valve 2 is the rear valve on the exhaust
W2004319
manifold. It connects to the lower 7–pin connector on the
wiring harness box.

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.

When the pulse EGR system causes exhaust pressure

to be momentarily higher than intake pressure, the reed
valves open. This allows cooled exhaust gases to pass
from the EGR cooler into the mixing chamber.

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.

The temperature sensor also is used to monitor for

abnormally high temperature. If temperature is excessive,
or if temperature remains above high for more than 30
minutes within an hour, the EECU will limit engine power
to protect the engine.

W2004307
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 10.2003 254 02 5(6)

EGR Valve Function

The EGR valves are normally closed with engine coolant
temperature below 65 C (149 F) unless the EMS has
the cooler in automatic cleaning mode.

EGR valve openings occur when engine coolant

temperature is greater than 65 C (149 F), the engine
load is greater than 50%, and the engine RPM is greater
than 1200. The valves open approximately 90% when
these conditions are met.

For idle EGR the engine coolant must be greater than 65

C (149 F), with the accelerator and clutch pedal at rest
(manual transmission). After 3 minutes of idle time, the
EMS reads the EGR temperature. If the EGR temperature
is above 98 C (208 F), the valve will remain open. If
the temperature at any time falls below 98 C (208 F),
the valve will be closed. The valve opens approximately
14% for idle conditions.

At all conditions when idle EGR is active, it is combined

with EPG to increase exhaust pressure in order to push
the exhaust gas over to the inlet side. The pulses do not
provide sufficient pressure by themselves to do this when
there is no engine load.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 10.2003 254 02 6(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).

To protect engine components from corrosion, the EGR

flow is stopped in conditions where condensation might
occur or where there is a risk of condensation. The
engine ECU evaluates RPM and torque load, ambient
temperature, inlet manifold temperature, and EGR
demand. With these inputs the EECU calculates the
dewpoint in the inlet manifold and limits the EGR opening
to constantly stay above the dewpoint.

To further protect the engine from wear particles, the

intake manifold and mixing chamber are surface-treated
to resist corrosion.

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.

The EECU also monitors the EGR valve position sensor.

It ensures that a valve position request is mirrored in the
position sensor signal, indicating the valve is actually in
the requested position.

The temperature sensor in the reed valve housing

provides the EECU with information on the state of the
reed valves as well as the EGR cooler.

A degraded EGR cooler will result in lower cooler

efficiency. Efficiency is calculated using the EGR
temperature, coolant temperature, and calculated exhaust
temperature. An EGR cooler clogged with soot deposits
will result in a fault code set by the EECU.

If the EGR temperature exceeds 205 C (401 F), the

next 3 cold starts the EGR valves will open when the
coolant temperature is above 25 C (77 F) and below
70 C (158 F) which creates condensations in the EGR
cooler. This condensation washes the soot out of the
cooler.