The value of the element of the exhaust gas recycling system for both ecology and for the Ford Transit engine. What is the EGR valve and the types of its designs
What is EGR?
EGR - exhaust gas recirculation system. From the name it is clear that when you work this system Returns part of the exhaust gases from the graduation in the intake manifold. The main task of the system is to reduce the exhaust toxicity in the warm-up modes and the sharp acceleration of the engine, which works on these modes on the enriched fuel mixes. In general, nothing complicated, but for some reason this system complicates the life of many engaged in the repair of cars so much.
First of all, consider the composition of the system:
1) The main part is the EGR valve. Provides gases from the exhaust to the intake manifold. Due to permanent contact with grilled gases - the least living part of the system. The main, it is the most important malfunction - leakage. In different modifications of the EGR system can be controlled as electrically ( most of Car GM) so and pneumatically (the bulk of cars).
2) EGR solenoid. Used in valve pneumatic systems. The main fault is the same as for the valve - a leaky and at work of the engine affects the same way as as a result we also get an EGR open valve.
3) EGR valve valve stem position sensor / EGR valve discovery sensor. It happens that they break, but besides the tanned engine malfunction lamps unpleasant consequences not visible.
4) Engine control unit.
Different systems There may be a different set of components, but the general is the EGR valve. Consider how its faults are affected by the engine. I already wrote that the main malfunction is leakage and it provides additional air seats in the intake manifold.
As a result, we have:
In engines with air flow meter (MAF-sensor) - depletion of the fuel mixture caused by the presence of an unrecorded air maf.
In engines with pressure sensor (MAP sensor) - enrichment of the fuel mixture caused by an increase in pressure in the intake manifold.
In engines using both ways to control the amount of air (due to the significant error of the MAF sensor with a low stream through the sensor), we have idling and sharp depletion at transient modes ( Japanese cars - the brightest examples).
And in all cases due to reducing the amount of oxygen in the air entering into the engine, the combustion of the fuel mixture in the engine cylinders is disturbed. In general, the dependence is very complex and on this malfunction of the EGR system on different models of cars manifested in different ways. The number of exhaust gases arriving in the intake manifold (i.e., the opening value of the EGR valve), the overall state of the engine (wear of the ignition candles, the problems of the fuel pump, or the fuel injector slab, the frequency of rotation and the load on the engine are wondering how the condition is interesting. fuel system affects symptoms of non-permistry? The fact is that any engine control unit has a program on which it seeks to stabilize the frequency of revolutions idle move and the composition of the fuel mixture. Moreover, the magnitude of the regulation of the discovery / closing of the actuator mechanism of the system for regulating the idle speed and the duration of the injection time has completely understandable limits. When the control unit is able to stabilize the idle course, in transient modes, it will not cope with the necessary correction of the composition of the mixture, so as pressing the accelerator pedal will lead to an increase in pressure in the graduation range and increase the amount of exhaust gas applicants that do not contain the necessary combustion oxygen. At this stage, all this will worsen the accelerated dynamics of the car, the appearance of failures and jerks when moving. But then the picture of the fault will be changed. The fact is that the split gases interacting with the oil mist in the intake manifold (if you forget where it comes from there, I will remind you about the crankcase ventilation system, the PCV valve will lead to the enhancement of nagarization on the internal parts of the collector, nagar deposits on intake valves, increased contamination of the exterior The parts of the fuel injectors and the appearance of the soot on the insulators of the spark plugs. All this will affect the starting characteristics of the engine and unstable idle turns, and it is possible both jamming and ignition passing and swimming. harsh pressed On gas, the appearance of flashes in the intake manifold. If you do not pay attention to the car at this stage, it is very soon idling completely, or its value will exceed all the permissible limits. And on machines with automatic transmission, a high idling value will very quickly lead to a breakdown of the box.
What to do with it? In any manuals for repair and maintenance it is written that eGR system It has a limited resource. Ideally, it is necessary to replace all components of the system when running 70-100 thousand kilometers, however, this is true with quite high-quality fuel. With Russian gasoline, I could recommend that you replace all components when running 50,000 kilometers. Although in the conditions of the crisis for many it is unrealistic.
What to do to those who cannot afford the acquisition of expensive components, or does not have the ability to purchase the necessary parts. Council One - timely service of the system will extend its service life. What can you have in it and need to serve?
First of all the EGR valve itself. It is necessary to clean the saddle and the valve stem to ensure the tight closure and freedom of the valve stroke. To do this, it is very convenient to use a liquid for cleaning the carburetor in the aerosol packaging. However, we are attentive to enter the fluid on the diaphragm may cause its destruction, since the substances included in the aerosol decompose the rubber.
Secondly, the EGR solenoid (if available). As a rule, contains a small filter to protect the vacuum system from falling into it. It is this filter that needs to be cleaned.
Well, that's the whole list of elements in need of periodic maintenance. By the way, this service is capable of returning many systems to life. Many - but not all.
Is it possible to turn off the system and normalize the engine operation? It is possible, it is enough to cut out of a thin fuster gasket under the EGR valve without cutting holes for the passage of gases. Carefully look at the valve if the rod protrudes for the planting plane, do the hole below it. That's all, but I immediately want to upset the owners of many Fords - the EGR health control system will definitely lit MIL. So you have to put up with a burning light bulb on dashboard. Chrysler and GM owners are easier - with such a disconnection, the lamp does not light up
Every year, automakers are becoming increasing attention to ecology issues. To improve this kind of systems, colossal money is spent.
Not an exception to the largest player of this market - the company Ford.. It actively invests millions of dollars in projects to reduce the harmful effect on the environment.
As a result of the introduction of hard standards in this direction, engineers were developed and implemented recycling system exhaust gasesor abbreviated EGR, for gasoline and diesel power units.
What is its meaning
It effectively neutralizes the destructive effect of nitrogen oxides, which helps reduce the level harmful emissions And accordingly increases the Eurostandard of the engine.
The principle of its action is reduced to the fact that in certain modes of operation of the motor, at idle and small revolutions, some of the exhaust gases comes from the exhaust manifold right in the inlet, on high revs their number is reduced by the activity of the special valve.
Thus, when mixing these gases with oxygen, the content of the latter is reduced. As a result, there is a decrease in the combustion temperature, which directly affects the reduction of toxicity.
According to expert estimates, the working condition of this system in the diesel engine leads to a reduction in the emission of soot microparticles by 10%, which, to some extent, affects the decrease in the growth of cancer.
Principle of operation of valve EGR on the example of Ford Transit
This model is very popular in the segment of commercial vehicles, where high annual runs are observed. In this regard, when buying, the choice falls on diesel modifications equipped with EGR system.
Its most important component is the valve, and the existing differences are reduced to the method of control. Thus, it can be electropneumatic, which corresponds to the standards of Euro-2 and Euro-3, as well as electronic - Euro-4 and Euro-5.
The main function of this device is to regulate the number of exhaust gases entering the intake manifold.
Painful choice: environmental safety or personal financial condition
Over time, from the quality of our fuel Ford Transit Valve Erg Slagey is clogged, which prevents its correct work.
The question arises about its replacement or plug. The first option is preferable, however, on the engine 2,5d, even the manufacturer itself admits the procedure for its neutralization.
It should be remembered that the faulty state of this component of the recycling system of exhaust gases is much worse on the environment, rather than its complete shutdown.
Programmatically plugged EMP Ford Transit Connect 1.8 TDCI. Release car 2010. Diesel engine 1.8 liters, with a capacity of 110 hp The diagnostics has shown one error in the P0409 engine - exhaust recycling (EGR) - a malfunction of the electrical circuit.
Reading and editing firmware
For Ford Transit Connect 1.8 TDCI Installed engine control Siemens SID 206, read and write firmware through diagnostic connector CMD Flash licensed flashaker. The feature of the Siemens control blocks is the complexity of disabling errors in the USR and so that during diagnostics in the future there is no "zero" malfunction code P0000 or P167F. 
We met cars with the disabled EGR and the "hanging" error P0000, while the machine was in emergency mode. Or another case, when the engine errors did not appear at all in any malfunctions.
Difficulty when editing Siemens files occurs due to lack of error masks location logic. To find the necessary, it is necessary to disassemble the firmware that we have done using Ida Pro. Only in this case it is possible to remove the errors and turn off the emergency mode of operation of the engine only when the USR is malfunction, while the P0000 and P167F will never appear. In addition, we closed the valve at the program level, although in the absence of nutrition, the USR is always closed with a return spring.
The result of the disconnection of the USR
Fix physically valve required, because Initially, it does not depend in the open position, which is due to a large amount of soot in the intake manifold or malfunction of the EGR mechanism (for example, the gears are checked). The engine came out emergency regime Works, errors in the valve EDR is not. About the pros and cons of disconnecting valve EGR. You can read on our website. 
The performance of the work took 1 hour.
Cars Ford, like the rest of the European, American machines, from the conveyor are equipped with a system of additional purification of exhaust gases. To do this, the EGR valve is installed under the hood of the car. This is due to the international requirements of the ECO commissions.
However, after 5 years of operation vehicleThe Valve EGR comes into disrepair. The cleaning system is clogged with soot and triggers the opposite effect. Washing valve EGR, scored by the soot system no longer cleans traffic fumesand on the contrary ejals into the atmosphere through exhaust pipe Machines even more "dirt". Due to the spoiled valve, the ERC exhaust becomes black, which means pollution of the environment, and the car loses its potential properties - the speed is dropped, the engine is clogged, the "Check" lights on the driver's dashboard lights up on the driver's dashboard .
It is possible to solve this problem in the Ford machines only by competent removal of the USR valve, a small system adjustment, as well as a special firmware of the electronic control unit.
Removing EGR, flashing ECU on Ford
On cars of Ford (as in many other foreign cars), removal of valve EGR in obligatory Must be accompanied by reprogramming the electronic engine control unit (ECU). This is explained by the fact that all electronic elements under the hood so or other intersect with the ECU, the electrical panel is closed, and the program installed by manufacturers directly interact with each sensor or device, and the EGR valve is not an exception.
Thus, if you just find the EPR valve under the hood, cut it and then connect the exhaust system directly, the engine of this "will not understand." According to the installed program, the computer will still turn to the EGR valve, search for information about its condition, read the data from the oxygen sensor, etc. Accordingly, the error will not disappear anywhere, the engine and exhaust system Anyway will work incorrectly. And the absence of an EGR valve with a non-remote error in the ECU can lead to more disastrous consequences and deterioration of the engine!
Professional Removal of Valve ERG
Masters of car service Hepesty in Ramenskoye (near Moscow, Lyuberts, Zhukovsky) are professionally engaged in reprogramming electronic components. In the service center, experts competently remove the USR valve for Ford, and then reflash the electronic unit Control. With the memory of a computer, Ford simply deletes information about EGR and the sensors associated with it, and the system is electronically adjusted so that exhaust gases will no longer be sent through the EGR system, and they will go directly into exhaust through subsequent filters.
The Speed \u200b\u200bLaboratory Company performs chip tuning of diesel turbocharged easy engine Commercial transport Ford Transit. Connect 1.8 TDCI.
Performing chip tuning work, our company can solve the following tasks:
An increase in engine power and improving its controllability;
Removal squeeze filter (DPF);
Disconnecting valve valve exhaust gases (EGR / EGR).
The operation of the specified Ford Engine Transit Connect 1.8 TDCI is controlled by the Siemens SID 206 block.
Motor Chipovka Ford Transit Connect 1.8 TDCII is across through the OBDII diagnostic connector. Programming is performed using professional Flasher KESS V2 from Italian partners - Alientech.
The connector is located on the left of the steering column behind the plastic panel:
As a result of flashing the ECU engine, the Ford transit Connect 1.8 TDCI increases the pickup at low and medium turns, the thoughtfulness of the "gas" pedal decreases and the maximum power and motor torque increases in 20%. With a quiet manner of car management, if the engine is not strongly "spinning", the clients there are significant fuel savings.
Also in the program there are settings for shutting down the recycling valve valve of exhaust gases - the removal of the USR.
The USR is located in the back of the engine as shown by a yellow circle in the picture below.
A large Nagar is formed to the USRT, which at the beginning will interfere with the valve open on the desired value and will be diagnosed with errors in the positioner. In the event that it does not close to the end, we will install the plug to ensure the tightness of the intake system.
One more trouble this engine - Dairy filter - it is possible to decide in our company. After reprogramming, our specialists physically remove its cells. By the way, the Syazhevik on the dyplanse cars is not, only on the imported used in Russia
