1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com EGR Adapter Audi/VW 3.0L Part No. 069-3391 EGR System Consists of: • Cold side EGR valve (after EGR cooler) controls exhaust gases for proper emissions control of No x gases • EGR cooler (controls temperature of exhaust gases to the air intake to the engine) • EGR cooler bypass valve (controls exhaust flow temperature to the air intake from the exhaust through the EGR cooler) • EGR temperature sensor (measures EGR cooler exhaust temperature and efficiency) • Swirl flaps (control airflow under different engine speed and loads) – closed when engine is at idle and at low engine speeds – below 1250rpm 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. Add Part#400-3012 DieselTune™ Max Strength Fuel Injector Cleaner to the vehicle’s fuel tank. 2. Remove plastic engine cover. 3. If engine is hot, the EGR cooler must be cooled – see step 9. 4. Specialty Socket – see next page CAUTION: Always wear gloves and safety glasses when performing this service
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1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com
EGR Adapter Audi/VW 3.0L Part No. 069-3391
EGR System Consists of:
• ColdsideEGRvalve(afterEGRcooler)controlsexhaustgasesforproperemissionscontrolofNoxgases
• EGRcooler(controlstemperatureofexhaustgasestotheairintaketotheengine)• EGRcoolerbypassvalve(controlsexhaustflowtemperaturetotheairintakefromtheexhaustthrough
theEGRcooler)• EGRtemperaturesensor(measuresEGRcoolerexhausttemperatureandefficiency)• Swirlflaps(controlairflowunderdifferentenginespeedandloads)–closedwhenengineisatidleandat
lowenginespeeds–below1250rpm
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. Removeplasticenginecover.3. Ifengineishot,theEGRcoolermustbecooled–seestep9.4. SpecialtySocket–seenextpage
CAUTION:Alwayswearglovesandsafetyglasseswhenperformingthisservice
Locations of EGR components:
• EGR cooler bypass valve vacuum hose• EGR temperature sensor • EGR valve
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Tools and Adapters Required:
069-3391
FRXM17
500-0170
5. RemoveEGRtemperaturesensor(seefigurebelow)usingaspecial17mmsocket.Donotdisconnectwireconnector.
6. Install069-3391initsplace(seefigurebelow).7. AttachEGRtooltoEGRadapter069-3391.Ensureairvalveandfluidvalveareclosed–seeEGRtool
userguide.
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8. Unscrewfillcapandfillwith32oz(946mL)ofPart#400-0280EGRSystemCleaner.Forfirstapplicationorseverecoking,64oz.mayberequired.
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, ignition must be off for the EGR to be closed. Open canister air valve, close canister fluid valve and flush cooler with air for 2 minutes.
10.Startvehicleengine.Usingthescantool,commandtheEGRclosed.DisconnectEGRcoolerbypassvalvevacuumhose(seefigurebelow)thiswillclosetheEGRbypassvalve.Note:IfnoscantoolisavailabledisconnecttheEGRwireconnector(seefigurebelow)thiswillclosetheEGRvalve.
11.OpenAirvalve,adjustregulatortomaintaininitialpressure,thenopenthefluidvalveonthetool.12.After1/4ofthefluidhasbeenconsumed,turnthefluidvalveoffandlettheairflowforanadditional2
minutestoflushdepositsintoexhauststream.13.Repeatstep10-12allowinganother¼ofthefluidtobeconsumed.Note:DuringthisstepcycletheEGR
coolerbypassvalve(seefigure2)severaltimesusingthescantool.ThiswillallowcleaningoftheEGRcoolerbypassport.
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1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com
ZIM14-01028
Note: If no scan tool available unplug and reconnect the EGR bypass valve actuator vacuum hose (see figure below) several times through out this step.
14.Usingascantool,commandtheEGRvalveandswirlflapsopen.Note: If no scan is available reconnect the EGR wire connector, raise engine rpm to 1500 this will allow the EGR and the swirl flaps to open.
15.Openfluidvalve.ContinueserviceuntilEGRtoolisempty.Note: At any time during the intake service (step 15) you hear a diesel knock sound, turn fluid valve to closed position for 2 minutes. After two minutes then turn fluid valve to open position and continue service. Let the vehicle operate for an additional 5 minutes and rev the engine several times to clear all residual fluid.
16.Turnthefluidandairvalveontooltotheclosedposition.TurnVehicleoff.Detachshopairlineanddepressurizethetoolbyrotatingtheregulatorknobcounterclockwise.
17.Removeadaptorandreassemblevehiclecomponentsinthereverseorderofremoval.WipeoffEGRtemperaturesensorusingtheEGRcleaningfluidbeforeinstalling.
18.AddonebottleofPart#400-3022DieselTune™CompleteFuelSupplementtovehicle’sfueltank.19.Afterservice,resetanyenginecodesandperformaroadtesttoclearanyresidualfluidfromthesystem.
VehiclemaygothroughRegencycleduringroadtest.
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