42 04

VACUUM MODULATOR

COMPOSITION
Layout

EGR valve

Turbocharger
actuator

Vacuum pump hose

Vacuum pump

Turbocharger vacuum modulator

EGR vacuum modulator

Vacuum Modulator for VGT Vacuum Modulator for EGR Valve

Turbocharger Actuator Control

IP internal fuse Engine ECU

IP internal fuse Engine ECU (RH) No.63-7.5A No. 96
(RH) No.63-7.5A No. 95

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REMOVAL AND INSTALLATION OF EGR VALVE

GENERAL
EGR Valve and Pipe
1. Remove the inlet hose to the intake manifold and disconnect the vacuum hose of the EGR valve.

ASSY
Inlet hose to Intake Manifold Vacuum Hose to EGR Valve

HOUSING
EXHAUST I N T A K E
Tightening torque
6 ~ 7 Nm

LUB
2. Remove the mounting bolt/nut to remove the left pipe of the EGR valve and unscrew four hexagon bolts to remove
the EGR valve assembly.

COOLING
EGR Valve Pipe (LH) EGR Valve Assembly

Tightening torque (bolt)

10 ± 1.0 Nm

FUEL
CONTROL
SENSOR
Tightening torque (bolt) Tightening torque (hexagon bolt)
10 ± 1.0 Nm 10 ± 1.0 Nm

3. Remove the right pipe of the EGR valve and remove the center pipe.

EGR Valve Pipe (RH) EGR Valve Pipe (Center)

Tightening torque (bolt) Tightening torque (M8 X 30)

10 ± 1.0 Nm 25 ± 2.5 Nm

Tightening torque (nut) Tightening torque (M8 X 25)

35 ± 3.5 Nm 25 ± 2.5 Nm

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4. Install in the reverse order of removal.

NOTICE
1. Observe the tightening torque of the bolts and nuts when installing pipes.
2. Replace the gaskets of the pipes with new ones. The protruding side should face to pressurized section.

EGR RH Pipe and Gasket EGR LH Pipe and Gasket

Center pipe bolt (2 EA) Intake pipe bolt (4 EA)

(M6 X 16: 10 ± 1.0 Nm) (M6 X 16: 10 ± 1.0 Nm)

Exhaust manifold nut (2 EA)

(M8: 35 ± 3.5 Nm)

* M8 mounting nut should be replaced with new one.

EGR valve

Center Pipe EGR Valve

Center pipe upper bolt (2 EA) EGr valve mounting bolt (4 EA)
(M8 X 25: 25 ± 2.5 Nm) (M6 X 25: 10 ± 1.0 Nm)

Center pipe lower bolt (2 EA) LH pipe mounting bolt (2 EA)

(M8 X 25: 25 ± 2.5 Nm) (M6 X 16: 10 ± 1.0 Nm)

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Inspection for EGR System

GENERAL
If the EGR system is malfunctioning, the engine power may be decreased or the exhaust gas may be increased. If
these happen, troubleshoot the system according to the following procedures.

ASSY
1. Inspection for EGR vacuum system
Check the EGR vacuum system (engine vacuum pump - vacuum modulator for controlling EGR valve - EGR valve) for

HOUSING
malfunction. Specifically, check the vacuum hose, connections, kinked hose and leaks due to interference with
surrounding components. Also check the EGR vacuum modulator's wiring connector. Make sure that the vacuum
system source functions properly by checking the engine vacuum pump for leakage.

EXHAUST I N T A K E
EGR valve
Main vacuum when
idling: 690 mmHg

LUB
Vacuum modulator
for turbocharger Brake booster
actuator

COOLING
IWE locking
hub

FUEL
Vacuum modulator
for EGR valve

CONTROL
2. EGR related DTC check using SCAN-100
Connect the SCAN-100 to the CAN module and check if

SENSOR
there is any DTC related to EGR.
If DTC is appeared, it may be due to the vacuum system.
Therefore, check the EGR system again.

DTC Related to EGR System

P0400 Faulty EGR valve control

P1405 Short circuit to EGR vacuum

modulator (GND)

P1406 Short circuit to EGR vacuum

modulator (B+)

All DTCs are related to EGR valve vacuum modulator.

Therefore, check the power supply and ground con-
dition by performing the following electrical check
for EGR valve vacuum modulator.

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3. Electrical check for EGR valve vacuum modulator

The EGR valve vacuum modulator is supplied with power from the main relay and fuse No. 63 (7.5 A) in the interior
fuse box which is located in the instrument panel (RH). Therefore, those relays and fuses should be checked first.
The vacuum modulator for the VGT turbocharger actuator is installed on the top of the vacuum modulator for EGR
valve. Both are supplied with the same power and controlled (duty cycle) by engine ECU. The following is the
procedure for checking the power supplied to the vacuum modulator.

IP Interior Fuse Box (Passenger Side) Vacuum Modulator

Engine ECU
main relay Vacuum modulator for VGT
turbocharger actuator
VGT & EGR vacuum
modulators, HFM

Vacuum modulator
for EGR valve

HP pumpIMV
Hazard Connector
warning lamp

Connector Installtion of multimeter

Terminal No. 1

IP interior fuse (RH) Engine ECU

No.63-7.5A No. 96

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GENERAL
4. EGR valve check
If there is no problem found so far, check the EGR valve as a unit.
The EGR valve is working as a passage for exhaust gas. It may not operate due to the contamination by the carbon
or other foreign materials.

ASSY
Check the unit according to the following procedures.

HOUSING
1. Remove the intake inlet hose. 2. Connect the vacuum tester to EGR valve.

EXHAUST I N T A K E
LUB
COOLING
3. Check if EGR valve starts to open when the vacuum 4. Check the conditions of EGR valve.
gauge indicates approx. 220 ~ 250 mmHg.

If the valve is severely contaminated, completely wipe FUEL

CONTROL
SENSOR
it out with soft cloth. Be careful not to damage it.

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REMOVAL AND INSTALLATION OF VACUUM MODULATOR ASSEMBLY

Removal and Installation
1. Separate the vacuum hose to EGR valve (1), the vacuum hose to turbocharger (2) and the vacuum hose to
vacuum pump (3) in turn.

EGR valve vacuum hose Vacuum pump hose

Vacuum hose for

turbocharger actuator

Brake
booster

IWE locking hub

2. Disconnect the vacuum modulator connectors 3. Unscrew the mounting bolts and remove the
to turbocharger (A) and EGR valve (B). vacuum modulators.

Tightening torque
10 ± 1.0 Nm

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GENERAL
4. Unscrew the mounting bolts and remove the
vacuum modulator bracket.

ASSY
HOUSING
EXHAUST I N T A K E
Vacuum modulator

5. Install in the reverse order of removal.

LUB
COOLING
FUEL
Components

Vacuum modulator for VGT

Bracket turbocharger actuator

CONTROL
Port to VGT turbocharger actuator

SENSOR
Port to vacuum pump

IP internal fuse (RH) Engine ECU

No.63-7.5A No. 95
Port to EGR valve

Vacuum modulator for EGR valve

IP internal fuse (RH) Engine ECU

No.63-7.5A No. 96

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ELECTRICAL CIRCUIT RELATED TO VACUUM MODULATOR

Main relay

Engine ECU

Vacuum modulator Vacuum

for VGT turbo- modulator for
charger actuator EGR valve

Engine extension wiring

IP Fuse Box (Passenger Side) Engine Main Relay & Fuse No. 63

Engine main relay

Fuse No. 63 (7.5A)

Fuse No. 63 (7.5A)

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Operation Principle of Vacuum Modulator

GENERAL
Vacuum
pump

ASSY
Output vacuum

HOUSING
ATM

Plunger

EXHAUST I N T A K E
Connector

LUB
COOLING
Vacuum
control
Diaphragm

FUEL
Seat assembly
Atmospheric pressure Spring
Plunger

CONTROL
SENSOR
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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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 Stroke

(mm)
Max. Distance
DUTY 50% 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 characteristics
Output vacuum (-mmHg)

Up

Down

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Operating conditions

GENERAL
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)

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

HOUSING
7. EGR OFF under extended period of idling.

EXHAUST I N T A K E
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
4) Intake air temperature (HFM): Decreases when over 60°C

LUB
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.

COOLING
Shut-off conditions

FUEL
1. Engine rpm: over 2,950 rpm
2. Vehicle speed: over 105 km/h
3. Coolant temperature: over 100°C or below 10°C

CONTROL
4. Idle period: over 50 seconds

SENSOR

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