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)

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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.

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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.

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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