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TECHNICAL INFORMATION

DIESEL
PARTICULATE
FILTER CLEANING
TECHNICAL MANUAL

Includes the cleaning of

EGR Valves | Temperature Sensors | Throttle Bodies

The Complete Servicing of the Fuel System

Innovative
Technologies TUNAP | Chemistry with Drive
TUNAP AUTOMOTIVE

TUNAP | Success from Innovation

TUNAP: Success Through Innovation and Concept


Increasing maintenance intervals require greater demands in maintenance quality. Rising
costs also necessitate creative concepts and systems to optimise profits.

The largest profit potential for car dealerships and workshops lies in the After-Sales area.

TUNAP is your partner when you want to combine top-level maintenance and service
quality with effective profit concepts.

Our products and marketing concepts help you:

Save time
Improve your first time fix
Sell additional services
Improve customer satisfaction and customer retention

TÜV Certificated Fuel Service Products - 135, 137, 973, 983


The TUNAP Way
TUNAP has been making innovative breakthroughs in chemistry with its developments in
automotive solutions for over 30 years. Whether it’s cleaning, maintaining, protecting,
adhering or lubricating: through its premium quality, TUNAP has become the European
market leader in technical aerosols.

Our own developments, production and sales demonstrate our international expertise, as
does our co-operation with leading automotive manufacturers. TUNAP is practically inside
every vehicle and car brand.

Together with our co-operation partners both at home and abroad, we develop customised
solutions for improved mobility.

TUNAP Corporate Partners


Additional “Problem Solving and Solution Providing”
Products within the TUNAP range

• Engine and Fuel Protection Systems


o Fuel System
o Injector Cleaning for Petrol & Diesel
o Oil System
o Coolant System

• Air Conditioning Service

• Workshop Service Products


o Maintenance & Care
o Special Greases and Pastes
o Windscreen Washer System
o Electrics

• Brake Service

• Adhesive and Sealing


o Thread locker
o Flange Sealing
o Instant Adhesives
INDEX

Topic Page

Products:

TUNAP micrologic® PREMIUM 131/132 – DPF Cleaner / Flush 1

TUNAP micrologic® PREMIUM 129 – Soot and Carbon Buster 1

TUNAP micrologic® PREMIUM 138 – EGR and Intake System Cleaner 1

TUNAP 157 – Motor Interior Engine Cleaner 2

TUNAP 321 – Engine System 2

TUNAP micrologic® PREMIUM 184 - Particle Filter System Ingredient 3

TUNAP microflex® 983 - System ingredient Diesel B5-B100 3

DPF Cleaning Procedure Flow Chart 4

Safety Equipment 5

Diagnosis 5

Diagnostic Equipment 5

The Cleaning Procedure of the DPF and Other Associated Items 5

Results – DPF Clean 9

Results – Throttle Body 9

Results – EGR Clean 10

Help and Support 11

Contact Details 11
The Products.

TUNAP micrologic® PREMIUM 131

Set for Particle Filter Cleaner

131 Particle Filter Cleaner: A non-inflammable, metal-free special cleaner for cleaning and
removal of soot and carbon deposits in a diesel particle filter. 131 evaporates
without leaving a residue. Its unique wetting properties allow this cleaner to
loosen and clean off soot and carbon agglomerates from porous honeycomb
structures like those present in the particle filter.

132 Flushing concentrate: Neutral, ash and metal-free concentrate for flushing
after particle filter cleaning. 132 evaporates without leaving a residue. The
cleaning process leaves a clean and re-usable diesel particle filter.

Contained in a 131 set are:

• 1 x MP 131 Particle filter cleaner (1000 ml)


• 1 x MP 132 Flushing concentrate (500 ml)

TUNAP micrologic® PREMIUM 129

Carbon and Soot Remover


129 Carbon and Soot Remover: A unique product in the form of an aerosol which has
been especially designed to remove the soot and carbon on EGR Valves, injectors, etc.
This will aid the removal of components which are seized in or are excessively coated
with Carbon. The product MUST be allowed to SOAK for best results. For extreme cases
of carbon build up, apply once, leave to soak, remove as much of the carbon paste as
possible and repeat. For best results spray part with 138 after cleaning to leave a “keep
clean” coating.

TUNAP micrologic® PREMIUM 138

EGR and Intake System Cleaner


138 EGR and Intake System Cleaner: A product to remove the build-up of soot, light to
medium carbon and general contaminants found in the EGR valve, throttle body and
intake system. Ideal for cleaning contaminated sensors, glow plugs and injectors etc.
Tunap 138 can also be used to clean parts in situ on petrol vehicles. Tunap 138 leaves a
“keep clean” coating after cleaning.

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TUNAP 157 Motor Interior Engine Cleaner

157 Motor Interior Engine Cleaner: The fluid, highly effective cleaner from the engine oil
detergent range in the viscosity class 0WX. Tunap 157 ensures rapid removal and
dispersion of dirt and sludge deposits inside the engine. The contaminants are removed
when draining the old oil.

Application:

• Problems caused by delayed oil changes


• Where black sludge is suspected
• For hydraulic valve rattle
• For piston ring compression loss
• To be used after every DPF Clean to flush out all contaminants

TUNAP 321 Engine System

321 Engine System: Recommended for all petrol and diesel engines with or without
turbocharger, with or without catalytic converter or particle filter. Fully effective with all
mineral or synthetic oils in all viscosity classes including all international specifications.

To be used after a DPF clean where the existing oil has done less than 5000 miles to
neutralise all gases and soot found in the engine oil.

Over 5000 miles a full clean with TUNAP 157 and replacement of new oil and filter is
recommended.

Properties:

• Reduces frictional resistance by OMC2


• Cleans entire oil circulation system including the critical piston ring zone
• Frees stuck piston rings
• Protects against corrosion
• Neutralises aggressive combustion acids
• Extreme wear reduction
• Ensures induction improvement
• Protects from black sludge and its consequences
• Optimum running reliability

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TUNAP micrologic® PREMIUM 184

Particle Filter System Ingredient

Tunap 184 Particle Filter System Ingredient: A product to help prevent further blocking of
the DPF on those vehicles where short journeys have blocked the DPF. Tunap 184 reduces
the burn off temperature of the soot inside the Diesel Particle Filter. This will then allow the
vehicle to do its own re-generation even when the optimum temperature for regeneration
has not been reached due to incompatible driving styles. This product to be used after a
clean and regeneration has taken place using PREMIUM 131. The product is to be
added to the fuel tank (min of 10litres in the tank) every 3rd - 4th tank refill. Do not overdose.

TUNAP microflex® 983

System ingredient Diesel B5-B100

Tunap 983 - System ingredient Diesel: A modern Multiflex concentrate ingredient for all
diesel and bio-diesel mixtures from B5 to B100 with a highly active cleaning ingredient,
based on ROA-technology.

Properties:

• Strong injection system cleaner, cleans injectors, fuel line and tank
• Contains “clean burn” technology to ensure fuel is burnt clean reducing the risk of
contamination in DPF, EGR etc.
• Contains cetane booster. Boosts cetane level reducing risk of engine knock and pinking
• Contains anti-oxidants to prevent oxidation in the fuel system
• Removes moisture from bio-diesel. Safely carries moisture through the combustion
process reducing the risk of damage to the fuel system especially the fuel pump.
• Has “keep clean” technology. Adds a microscopic coating to prevent re contamination of
tank, fuel lines and injectors.
• Cleans intake valves (intake manifold injection), combustion chamber and exhaust valves
using the ROA-technology.
• Kills micro organisms eliminating the buildup of ‘diesel bug’, a bacteria that can cause
severe damage to the fuel system
• 1 x Application will service up to 80 litres of fuel and protect for up to 8000 miles
• Reduces emissions
• Improves fuel consumption
• Protects, Services and Cleans the whole Fuel System

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DPF – (Diesel Particulate Filter) Flow Chart

Warning light on dash Poor or No Performance

Check Diagnostic Equipment Ensure CORRECT diagnosis

Fault Codes Increased back pressure

Clean - £350 to £450 Clean or Replace the DPF Replace - £1000 to £3500

Check Diagnostic Equipment will Clean…??? Yes/No Do NOT attempt to do a clean


do a Re-Gen Do a Print off of DPF Stats without the ability to do a Re-gen

Check Condition of ALL Remove Temperature Clean Sensors with


pipes Sensor on the DPF TUNAP 138

Clean DPF/EGR Between each 20min


wait, remove the EGR
and clean with 129/138

Apply 50% of the 1ltr TUNAP 131 in 5 sec intermittent bursts – waiting 20 mins after application –
then apply the second 50% in exactly the same way – waiting 20 mins after application

Apply all the TUNAP 132 in 5 sec intermittent bursts – waiting 20 mins after application

Clear down ALL fault codes – Replace Sensor and EGR Valve
failure will result in aborted re- after Cleaning
gen

Remove vehicle outside to safe place…hold at 3000 RPM for 20 mins to


perform a ‘Burn - off’

Drive vehicle for 15/20 mins at 2500/3000 RPM to achieve a passive re-gen –
should vehicle not perform re- gen…do a forced re -gen and/or delete memory

Flush Engine Oil with 1 x TUNAP 327 If Engine Oil is less than 5000
New Oil & Filter miles old, add 1 x TUNAP 321

Add 1 x TUNAP 184 to a full tank of Add 1 x TUNAP 983 to a full tank of
Diesel to assist in Short Journeys Diesel to Fully Service the fuel system

Do a final print off of the DPF stats

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Safety Equipment.

Outside of normal H & S equipment which should be used within the workshop, we recommend that
the following should be used whilst doing a DPF clean.

• Safety Glasses
• Filter Mask
• Gloves
• Overalls

Any product should be removed immediately if it comes into contact with skin.

Should any product be taken or swallowed, please refer to the MSDS sheet. All MSDS sheets are
available for download at www.tunap.com.

Diagnosis.

It is important to understand why the DPF has blocked or failed.

Which fault codes are present and what effect these have on the DPF.

A thorough investigation must take place to ensure any other potential problems are removed

• short journeys & style of driving incompatible to automatic DPF regeneration


• poor fuel quality
• poorly operating or blocked injectors
• faulty EGR valve (Exhaust Gas Recirculation)
• incorrect engine oil
• service intervals exceeded
• split or damaged hoses
• fault codes showing on the diagnostic equipment linked to DPF/Exhaust

Diagnostic Equipment

It is vital that your diagnostic equipment will allow you to perform a regeneration. This is a critical
part of the DPF cleaning process. Should the vehicle not regenerate on the road test after the clean,
a forced regeneration must be done to complete the cleaning cycle and to re-set the codes in the
ECU.

It is also important that the diagnostic equipment is able to do a print out of the stats and readings.

The Cleaning Procedure of the DPF and Other Associated Items

1. Do a detailed diagnosis of the vehicle

2. Ensure the temperature of the vehicle is not greater than 80°C. If it is, please wait until
cooled.

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3. Connect the diagnostic equipment to the vehicle. Run diagnostics

4. Print off the stats of the DPF system, soot mass, back pressures, kilopascals etc.

5. Visually check all associated hoses for damage or splitting & replace as required.

6. Identify the DPF and where the temperature sensor on the DPF is located.

7. Remove the temperature sensor.

8. For DPF’s without a temperature sensor, undo the flange and slightly drop down to reveal
g of the DPF.
the opening DPF

9. Assemble the Tunap DPF gun & lance then connect the air-line adaptor N.B. the kit only
comes with one lance, this is the standard 5mm off-set. There are two other options
available as a 4mm probe and a 5mm straight probe with a front spray orifice.

10. Take the 131 and empty 50% of the product into the pot on the gun. Insert the probe into the
hole made by the removal of the temperature sensor. You may have to bend the probe
slightly, it is made of stainless steel and will re-shape quite easily. The probe is fitted with a
disc the size of a 2p piece, this must face you at all times ensuring that the jets of cleaning
product are firing away from you. You will be injecting the 131 into the flow of the
exhaust/DPF i.e. engine to tail-pipe. (see next page)

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11. With the probe at approximately the centre of the DPF face begin to inject the 131 into the
DPF. This must be done by pulsing i.e. 5 sec spray followed with 5 sec wait. Cleaning is
done in this way in order to saturate the carbon/soot in the DPF core. Keep this procedure
up whilst moving the spray jet head around inside the DPF to ensure you get total coverage
of the DPF core until pot is empty. When empty remove the probe and then let the 131 take
effect for 20 minutes.

12. During this waiting period, remove the EGR Valve. Using Tunap 129 and Tunap 138, clean
the valve and the temperature sensor which will be hanging beside the DPF.

13. TUNAP micrologic® PREMIUM 129 Soot and Carbon Remover: Spray the 129 into the
EGR chambers and allow time to soak. The severity of the carbonization will determine the
length of time. For heavy soiling, anything up to 30 minutes. The 129 will emulsify the carbon
from a hard substance into a paste. This is then ready to be cleaned off with the 138.

14. TUNAP micrologic® PREMIUM 138 EGR and Intake System Cleaner: Spray the 138 into
the EGR chambers and outer body cleaning off all the soot and carbon residues. Also use to
clean the temperature sensor as mentioned in point 12.

15. Returning to the DPF, pour the remaining 50% of the 131 into the gun pot and apply in the
same way as before, let the 131 take affect for a further 20 minutes, see point 11.

16. During this waiting period, finish off cleaning the EGR valve and temperature sensor and
then replace, ensuring that the EGR manifold connection is also carbon free.

17. After 20 minutes has passed, empty all of the 132 into the gun pot and administer in the
same way as before and let the 132 take affect for a further 20 minutes. See point 11.

18. Finish off by replacing the EGR valve and temperature sensor and replace any other parts of
the engine cowling etc which may have been removed, check coolant and oil levels etc.

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19. Remove the vehicle outside to a safe place as during the “burn off” there will be extreme
amounts of white steam & vapor.

20. Connect your Diagnostic Equipment & clear all fault codes.

21. Start vehicle and hold at 3000 RPM for 20 minutes. During this time (normally the first 10
minutes) there will be extreme amounts of burn off steam & vapor as well as black fluid
coming from the tail pipe. This is normal.

22. Immediately the burn off is complete take the vehicle for a drive and meet the manufacturers
criteria for passive regeneration.

23. Return to the workshop and complete a diagnostic test to see if the vehicle has done its own
regeneration, if not please perform a static regeneration. N.B. should the vehicle NOT
allow a static or forced re-generation, delete the memory of the DPF and try again.

24. Once the regeneration is complete it is now time to flush the engine oil with TUNAP 157
Motor Interior Cleaner: A blocked or failing DPF will dramatically increase the amount of
soot and contamination which will enter the engine oil. By flushing and cleaning with the 157,
you will remove around 97% of the old contaminants and oil. This will help to prevent further
contamination of the cleaned DPF and at the same time will thoroughly clean and service the
internal workings of the engine. To apply, empty the whole can into the engine oil and let
vehicle run at idle for 10/15 minutes. On completion, drain down and replace with new oil
and filter.

25. TUNAP 321 Engine System: For those engines that have recently had an oil change (within
5000 miles) you can add a 321 to the existing oil. This will address the contamination and
gases found in the new oil and help to protect the oil until its normal life expectancy. You can
use the 157 and then add a 321 to the new oil for top performance and protection.

26. TUNAP micrologic® PREMIUM 184: From the original diagnostics and evaluation, should it
be found that the main cause of the DPF failure was driving style where non-regeneration
has happened, empty the whole can of the 184 into a minimum of 10 litres of diesel. This will
then assist the customer in letting the vehicle perform a passive regeneration at a lower
temperature. Tunap 184 should be added at every fourth full tank of diesel.

27. TUNAP microflex® PREMIUM 983: Finally, to further assist in the cleaning and protection
of the whole fuel system and to help prevent further build-up of soot in the DPF, as well as
reduce emissions and increase fuel efficiency and performance, add 1 x 983 into the diesel
tank. One application will service the vehicle for up to 8000 miles. With its “Clean Burn”
technology, the fuel burnt in the engine will burn cleaner which in turn reduces the soot
accumulating in the DPF. For maximum effect, please empty the 983 into a to a full tank of
diesel and run down until the fuel light comes on.

NOTE: DO NOT LEAVE THE 131/132 IN A DPF OVERNIGHT. THIS WILL CAUSE IT TO
SOLIDIFY.

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Results.
A DPF filter
er before a clean.
cl Totally blocked. The same filter after
ter the clean.
clea 100% Clean

Results of Throttle Body and Butterfly Flap using MP138

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Results of EGR Cleaning using 129 and 138

EGR taken from vehicle After 10 mins Soaking

During Soaking in 129

After Soaking in 129 and Cleaning with 138

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Technical Support
It is TUNAP’s policy to help train and support our customers wherever possible. We are more than
willing to come to your premises and train your technicians in how to use our products to their
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Safety Data Sheets


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TUNAP | Chemistry with Drive