1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com

EGR Adapter MaxxForce 7 6.4LPart No. 069-3645

EGR System Consists of:

• ColdsideEGRvalve(AfterEGRcooler)controlsexhaustgasesforproperemissionscontrolofNoxgases• 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. Removeplasticenginecover.3. Ifengineishot,theEGRcoolermustbecooled–seenoteinstep8.

CAUTION:Alwayswearglovesandsafetyglasseswhenperformingthisservice

500-0170

Locations of EGR components:

• EGR Valve (figure 1)

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Tools and Adapters Required:

• EGR cooler temperature sensor (figure 2)

069-3645

Figure 1

Figure 2

4. RemoveEGRcoolertemperaturesensor(seefigure2).DisconnectEGRvalveelectricalconnectortoclosetheEGRvalve(seefigure3&4).

5. Install069-3645adapter(seefigure4)inplaceofaboveEGRtemperaturesensor.

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Figure 3

Figure 4

6. AttachEGRtool500-0170toEGRadapter069-3645.Ensureairvalveandfluidvalveareclosed–seeEGRtooluserguide.

7. Unscrewfillcapandfillwith32oz(946mL)ofPart#400-0280EGRSystemCleaner.Forfirstapplicationorseverecoking,64oz.ormoremayberequired.

8. Reinstallthefillcapandhangtoolfromthehoodlatch.Connectshopair.SetairpressureonEGRtoolto40-50psi.NOTE: If engine is hot, the EGR cooler must be cooled before treatment can start. Before step 9 can proceed, ignition must be off for the EGR system to be cooled. Open EGR tool air valve, keeping the fluid valve closed, and flush cooler with air for 2 minutes.

9. Startvehicleengine.10.OpenairvalveonEGRtool,adjustregulatortomaintaininitialpressureandthenopenthefluidvalveon

theEGRtool.11.After1/4ofthefluidhasbeenconsumed,turnthefluidvalveoffandlettheairflowforanadditional2

minutestoflushdepositsintoexhauststream.12.Repeatstep10-11allowinganother1/4ofthefluidtobeconsumed.13.ReconnectEGRtemperaturesensorelectricalconnectortoopenEGRvalve.14.Openfluidvalve.ContinueserviceuntilEGRtoolisempty.

Note: At any time during the intake service (step 14) 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.

15.Turnthefluidandairvalveontooltotheclosedposition.TurnVehicleoff.Detachshopairlineanddepressurizethetoolbyrotatingtheregulatorknobcounterclockwise.

16.Removeadapterandreassemblevehiclecomponentsinthereverseorderofremoval.WipeoffEGRtemperaturesensorusingtheEGRcleaningfluidbeforeinstalling.

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

ZIM15-01109