EGR Adapter Mercedes MBE4000 12 - CPS Products Inc. · the EGR valve was positioned. Rotate the EGR valve adapter counterclockwise and secure using the existing three screws (see

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EGR Adapter Mercedes MBE4000 12.8L

Part No. 069-3665

EGR System Consists of:

• ColdsideEGRvalve(afterEGRcooler),whichcontrolsexhaustgasesforproperemissionscontrolofNoxgases

• EGRcooler(controlstemperatureofexhaustgasestotheairintaketotheengine)• EGRtemperaturesensor(measuresEGRcoolerexhausttemperatureandefficiency)

These items are critical for proper emissions management control and must be cleaned on a regular basis for optimum efficiency.

First steps before any service can be performed:

1. AddPart#400-3012DieselTune™MaxStrengthFuelInjectorCleanertothevehicle’sfueltank.2. Removeplasticenginecoverandfoaminsulator.3. Ifengineishot,theEGRsystemmustbecooled–seenoteinstep9

CAUTION:Alwayswearglovesandsafetyglasseswhenperformingthisservice

500-0170

069-3399

Locations of EGR components:

• EGR cooler (figure 1)

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Tools and Adapters Required:

• EGR valve (figure 1)

069-3665

Intake

98821286

98821282

98821287

98821089

Exhaust

98821285

Figure 1

4. Removebothboltssecuringtheoilfillpipeandbracket(4bolts).RemovetheboltssecuringtheEGRcooleroutletpipetotheintake(2bolts).RemovetheboltssecuringtheEGRvalvecover(4bolts).RemovetheboltssecuringtheEGRcooleroutletpipebrackettotheintake(2bolts)(seefigure2).

5. RotateEGRcoolerpipe90°upwards,installsupportbracket(98821286)usingthetwobolts(98821089)securingthepipealongwiththetwonuts(98821282)supplied(seefigure3).InstallEGRintakeadapterusingtheexistingboltsandinstalltheEGRexhaustadapterusingthetwobolts(98821287)andtwonuts(98821282)(seefigure4).

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Figure 2

Figure 3 Figure 4

6. RemovethethreescrewssecuringtheEGRvalveandsetEGRvalveontoptheintake(seefigure5&5a).InstallEGRvalveopener(98821285)adapterbyaligningthetabontheadapterintheslotwheretheEGRvalvewaspositioned.RotatetheEGRvalveadaptercounterclockwiseandsecureusingtheexistingthreescrews(seefigure6&7).ThiswillopentheEGRflapinsidetheEGRcooleroutletpipe.

7. AttachEGRmanifold069-3399toEGRintakeandexhaustadapters(seefigure8).AttachEGRtool500-0170to069-3399.Ensureairvalveandfluidvalveareclosed–seeEGRtooluserguide.

Figure 5 Figure 5a

Figure 7Figure 6

Figure 8

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8. Unscrewfillcapandfillwith64oz(946mL)ofPart#400-0280EGRSystemCleaner.Forfirstapplicationorseverecoking,128oz.ormoremayberequired.Note: When using 128 oz, use 64 oz on exhaust side first then use 64 oz on intake side. In between exhaust and intake cleaning the air pressure must first be set to zero before adding the remaining 64 oz.

9. Reinstallthefillcapandhangtoolfromthehoodlatch.Connectshopair.SetairpressureonEGRtoolto40-50psi.NOTE: If engine is hot, the EGR cooler must be cooled before treatment can start. Before step 10 can proceed, open EGR tool air valve, keeping the fluid valve closed, turn valve on the EGR manifold adaptor 069-3399 to exhaust and flush cooler with air for 2 minutes.

10.Startvehicleengine.SetEGRmanifoldtoexhaust.11.OpenairvalveonEGRtool,adjustregulatortomaintaininitialpressureandthenopenthefluidvalveon

theEGRtool.12.After1/4ofthefluidhasbeenconsumed,turnthefluidvalveoffandlettheairflowforanadditional2

minutestoflushdepositsintoexhauststream.13.Repeatstep11-12allowinganother¼ofthefluidtobeconsumed.14.Setvalveonadaptertointake,openfluidvalveandcontinueserviceuntilEGRtoolisempty.

Note: At any time during the intake service you hear a diesel knock sound, turn manifold valve to off for 2 minutes. After two minutes then turn manifold valve to intake and continue service. Let the vehicle operate for an additional 5 minutes and rev the engine several times to clear all residual fluid.

15.Turnthefluidandairvalveontooltotheclosedposition.TurnVehicleoff.Detachshopairlineanddepressurizethetoolbyrotatingtheregulatorknobcounterclockwise.

16.Removeadaptersandreassemblevehiclecomponentsinthereverseorderofremoval.17.AddonebottleofPart#400-3022DieselTune™CompleteFuelSupplementtothevehicle’sfueltank.18.Afterservice,resetanyenginecodes.Thevehicleshouldthenbesettorunamanualregenerationcycle

orifthatisnotpossible,thevehicleshouldbedrivenathighwayspeeds(orinthecaseofnon-highwayequipmentoperatedunderaload)forapproximately30minutes.Thisisnecessarytoremoveallofthecleaningsolutionfromthepassagesandcooler(s)andtocombustanymaterialthathasreachedthedieseloxidationcatalyst(DOC)anddieselparticulatefilters(DPF).This should be done as soon as possible.

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