egr adapter mercedes mbe4000 12 - cps products inc. · the egr valve was positioned. rotate the egr...
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1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com
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.
1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com
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