● BG EF686 EGR round 3.12” intake adaptor, PN E101-1684
● BG EF642 EGR round exhaust adaptor, PN E101-1673
● BG EF399 EGR manifold, PN E101-1645
● BG 64 Diesel VIA® supply tool, PN E101-1642
● Scan tool to open the EGR valve
EGR System Consists of:
● Hot side the EGR valve (before the EGR cooler), which allows for proper emissions control of Nox gases
● EGR cooler (controls temperature of exhaust gases to the air intake to the engine)
● EGR temperature sensor (measures the EGR cooler exhaust temperature and efficiency)
These components are critical for proper emissions control and must be cleaned on a regular basis for optimum efficiency.
NOTE:Before starting the EGR cleaning service, inspect the EGR components for severe deposits or clogging. Manual cleaning may be required (by scraping, sucking, wiping, etc.) before performing the service.
1.Add BG 245 Premium Diesel Fuel System Cleaner, PN 245, to vehicle’s fuel tank.
2.Remove plastic engine cover and foam insulator.
3.Remove the clamps on the EGR cooler outlet pipe, which is located on the passenger side of the engine bay (Figure 2). Remove the EGR cooler outlet pipe and set aside.
Quick Tip: Place the EGR cooler outlet pipe into a container and fill the container with BG Diesel EGR System Cleaner, PN PD10, until submerged. This will aid in the dislodging of soot from the pipe while the EGR cleaning procedure is performed.
4.Install the BG EF686 intake adaptor using the existing clamps. Install the BG EF642 exhaust adaptor using the existing clamps and gasket (Figure 3).
5.Attach the BG EF399 manifold to the BG EF686 intake and BG EF642 exhaust adaptors. Attach the BG 64 Diesel VIA® supply tool to the BG EF399 manifold. Ensure that the air valve and fluid valve on the supply tool are closed (see supply tool instructions).
6.If the engine is hot, the EGR cooler must be cooled before treatment can start. Start the engine. Open the supply tool air valve, keeping the fluid valve closed. Turn the BG EF399 manifold to exhaust and flush EGR cooler with air for two minutes. Use the scan tool to open the EGR valve.
7.Unscrew fill cap and fill supply tool with 64 oz. (1.8 L) of BG Diesel EGR System Cleaner, PN PD10.
8Reinstall the fill cap and hang supply tool from the hood latch. Connect shop air. Set air pressure on the tool to 40–50 psi.
9.Start the vehicle engine. Ensure the BG EF399 manifold is set to exhaust. Using the scan tool,
command the EGR valve to open while the engine is operating. This will need to be repeated every minute during the exhaust portion of the service.
10.Open the air valve on the supply tool. Adjust the regulator to maintain the initial pressure of 40–50 psi.
Then open the supply tool fluid valve.
NOTE:In some engines, it will be necessary to increase the engine speed to just over 1,000 RPM in order to keep the engine running. Otherwise, the engine will shut off after five minutes of idling.
11.After ½ of the fluid has been dispensed, close the fluid valve and let the air flow for an additional two minutes to flush deposits into the exhaust stream.
12.Turn the BG EF399 manifold to intake. Open supply tool fluid valve and continue service until the supply tool is empty.
NOTE: If at any time during the intake service you hear a diesel knock sound, turn the BG EF399
manifold to off for two minutes. After two minutes, turn the BG EF399 manifold to intake and continue service.
13.When supply tool is empty, let the vehicle operate for an additional five minutes and rev the engine several times to clear all residual fluid.
14.Repeat steps 7–13 using 32 oz. (946 mL) of BG Diesel EGR System Rinse, PN PD11.
NOTE: For severe coking, it may be necessary to perform the service a second time to achieve desired results.