1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com EGR System Consists of: • 1 Hot side EGR valve (no EGR cooler), a high pressure loop which controls exhaust gases for proper emissions control of No x gases • 1 Cold side EGR valve (after EGR cooler), a low pressure loop which controls exhaust gases for proper emissions control of Nox gases located after DOC+DPF filter • EGR cooler (controls temperature of exhaust gases to the air intake to the engine) – low pressure loop only • EGR temperature sensor (measures EGR cooler exhaust temperature and efficiency) 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 system must be cooled – see note step 8. CAUTION: Always wear gloves and safety glasses when performing this service EGR Adapter VW (Engine Code CJAA/CBEA) 2.0 Liter TDI Part No. 069-3520
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
-
1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com
EGR System Consists of:
• 1HotsideEGRvalve(noEGRcooler),ahighpressureloopwhichcontrolsexhaustgasesforproperemissionscontrolofNoxgases
• 1ColdsideEGRvalve(afterEGRcooler),alowpressureloopwhichcontrolsexhaustgasesforproperemissionscontrolofNoxgaseslocatedafterDOC+DPFfilter
• EGRcooler(controlstemperatureofexhaustgasestotheairintaketotheengine)–lowpressurelooponly
• 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. Removeplasticenginecover.3. Ifengineishot,theEGRsystemmustbecooled–seenotestep8.
CAUTION:Alwayswearglovesandsafetyglasseswhenperformingthisservice
EGR Adapter VW (Engine Code CJAA/CBEA) 2.0 Liter TDI
Part No. 069-3520
-
Locations of EGR components:
• EGR valves – high pressure loop (figure 1)
[email protected] www.motorvac.com
Tools and Adapters Required:
• EGR valve and cooler found after DOC+DPF filter (figure 2) low pressure loop
• EGR temperature sensor on low pressure loop (figure 2)
Figure 2
069-3520
069-3399
500-0170
Figure 1
-
4. RemoveEGRinletpipebolts(seefigure3).PullbackEGRpipeabout½”andremovegasket.
5. Install069-3520initsplace(seefigure4)andusethetwosuppliedbolts(handtight)tosecuretheadapter.Ensurethattheadapterisinstalledasshown(couplerfacingup)forpropercleaningoftheEGRsystem.
[email protected] www.motorvac.com
Figure 3
Figure 4
-
6. AttachEGRmanifold(069-3399)toEGRadapter069-3520,thenattachaeratorassemblyto069-3399.Ensureairvalveandfluidvalveareclosed–seeEGRtooluserguide.
7. Unscrewfillcapandfillwith32oz(946mL)ofPart#400-0280EGRSystemCleaner.Forfirstapplicationorseverecoking,64oz.mayberequired.
8. Reinstallthefillcapandhangtoolfromthehoodlatch.Connectshopair.SetairpressureonEGRtoolto40-50psi.NOTE: If engine is hot, the EGR system must be cooled before treatment can start. Before step 9 can proceed, ignition must be off for the EGR system to be cooled. Turn valve to exhaust on EGR manifold, open canister air valve, close canister fluid valve and flush cooler with air for 2 minutes.
9. Startvehicleengine.SetEGRmanifoldtoexhaust(seefigure5).
10.OpenAirvalve,adjustregulatortomaintaininitialpressure,thenopenthefluidvalveonthetool.11.After1/4ofthefluidhasbeenconsumed,closethefluidvalveandlettheairflowforanadditional2
minutestoflushdepositsintoexhauststream.12.Raiseenginerpmto1200asthiswillopentheEGRvalve,turnadaptervalvetointake(seefigure6),
openfluidvalveandcontinueserviceuntilanother¼ofthefluidisconsumed.Note: If 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.
[email protected] www.motorvac.com
Figure 5
-
13.Closethefluidvalveandturnmanifoldvalvetoexhaust(seefigure5)andlettheairflowforanadditional2minutestocoolofftheexhauststream.
14.Openfluidvalveandcontinueserviceuntilanother¼ofthefluidisconsumed.15.Raiseenginerpmto1200asthiswillopentheEGRvalve,turnadaptervalvetointake(seefigure6),
openfluidvalvecontinueserviceuntilEGRtoolisempty.Note: If 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.Note: 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.18.AddonebottleofPart#400-3022DieselTune™CompleteFuelSupplementtothevehicle’sfueltank.19.Afterservice,resetanyenginecodesandperformaroadtesttoclearanyresidualfluidfromthesystem.
VehiclemaygothroughRegencycleduringroadtest.
1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com
ZIM14-01042
Figure 6
Related Documents
