VW 2005.
5-2006 Jetta
(Engine Code BRM) 1.9L TDI
Part No. 069-3565
CAUTION:
Always wear gloves and safety glasses when performing this service
EGR System Consists of:
• Cold side EGR valve (after EGR cooler), which controls exhaust gases for proper emissions control of
Nox gases
• EGR cooler (controls temperature of exhaust gases to the air intake to the engine)
• EGR cooler bypass valve (controls exhaust flow temperature to the air intake from the exhaust through
the EGR cooler)
• 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 DieselTune™ Max Strength Fuel Injector Cleaner (400-3012) to vehicle’s fuel tank.
2. Remove plastic engine cover.
3. If engine is hot, the EGR cooler must be cooled.
1324 Blundell Rd. Mississauga ON Tel. 905.615.8620 Fax. 905.615.9745 www.motorvac.com
Tools and Adapters Required:
500-0170
069-3565
069-3399
Locations of EGR components:
• EGR valve (Figure 1) • EGR cooler and bypass valve
(Figure 1)
Figure 1
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4. 4. Remove the 3 EGR valve bolts (see Figure 2).
Figure 2
5. Remove EGR valve and set on top of engine with the electrical connector attached. Install 069-3565 in
its place; install the 3 bolts hand tight.
6. Attach EGR manifold 069-3399 to EGR adapter 069-3565. Attach EGR tool 500-0170 to 069-3399.
Ensure air valve and fluid valve are closed – see EGR tool user guide.
7. Unscrew fill cap and fill with 32oz (948mL) of 400-0280 EGR System Cleaner fluid. For first application or
severe coking, 64 oz. may be required.
8. Reinstall the fill cap and hang tool from the hood latch. Connect shop air. Set air pressure on EGR tool to
40-50 psi.
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. Connect the hand
vacuum pump tool the EGR cooler bypass vacuum actuator (see figure 3), draw a vacuum as
this will close the EGR cooler bypass valve thus allowing cooling of the EGR cooler. 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.
9. Start vehicle engine. Set EGR manifold to exhaust . Disconnect EGR cooler bypass valve vacuum
actuator hose and attach a hand vacuum pump tool and draw a vacuum, this will close the EGR cooler
bypass valve and allow cleaning of the EGR cooler.
Figure 3
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10. Open air valve on EGR tool, adjust regulator to maintain initial pressure, and then open the fluid valve on
the EGR tool.
11. After 1/4 of the fluid has been consumed, close the fluid valve and let the air flow for an additional 2
minutes to flush deposits into exhaust stream.
12. Raise engine rpm to 1200, turn manifold valve to intake, open fluid valve and continue service until
another ¼ of the fluid is consumed.
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.
13. Close the fluid valve and turn manifold valve to exhaust and let the air flow for an additional 2 minutes to
flush deposits into exhaust stream.
14. Open fluid valve and continue service until another ¼ of the fluid is consumed. During this step cycle the
EGR cooler bypass valve several times by releasing the vacuum on your hand vacuum pump tool and
drawing a vacuum several times through out this step. This will allow cleaning of the EGR cooler bypass
port.
15. Turn manifold valve to intake, open fluid valve and continue service until EGR tool is empty.
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 engine run for an additional 5 minutes and rev the engine several times to clear
all residual fluid.
16. Turn the fluid and air valve on tool to the closed position. Turn Vehicle off. Detach shop air line and
depressurize the tool by rotating the regulator knob counter clockwise.
Note: Disconnect the EGR valve electrical connector and clean the EGR valve with EGR
cleaning fluid using a soft bristle brush before starting step 17
17. Remove adapter and reassemble vehicle components in the reverse order of removal.
18. Add DieselTune™ Max Strength Fuel Injector Cleaner (400-3012) to the vehicle’s fuel tank.
19. After service, reset any engine codes and perform a road test to clear any residual fluid from the system.
Vehicle may go through Regen cycle during road test.
ZIM16-01733
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