Exhaust Gas Recirculation Cooler Page 1 of 8
011-019 Exhaust Gas Recirculation Cooler
Preparatory Steps
WARNING
Coolant is toxic. Keep away
from children and pets. If not
reused, dispose of in
accordance with local
environmental regulations.
l Drain the engine coolant.
Refer to Procedure 008-
018 (Cooling System) in
Section 8.
l Remove the exhaust
pressure sensor tube.
Refer to Procedure 011-
027 (Exhaust Gas
Pressure Sensor Tube) in
Section 11.
l Remove the EGR cooler
coolant lines. Refer to
Procedure 011-031 (EGR
Cooler Connection) in
Section 11.
l Remove the EGR cooler
connection. Refer to
Procedure 011-024 (EGR
Cooler Connection) in
Section 11.
l Remove the EGR
connection tube. Refer to
Procedure 011-025 (EGR
Connection Tubes) in
Section 11.
l Remove the EGR valve
coolant return line. Refer
to Procedure 011-030
(EGR Valve Coolant
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Exhaust Gas Recirculation Cooler Page 2 of 8
Lines) in Section 11.
Remove
NOTE: When replacing the
EGR cooler, it is not
necessary to remove the
brackets and clamping
straps. New EGR coolers
come as an assembly with
all brackets and clamping
straps already installed.
Remove the two capscrews
that hold the EGR cooler and
bracket assembly to the
cylinder head.
Remove the EGR cooler as
an assembly.
Clean and Inspect for Reuse
WARNING
When using solvents, acids,
or alkaline materials for
cleaning, follow the
manufacturer's
recommendations for use.
Wear goggles and protective
clothing to reduce the
possibility of personal injury.
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Exhaust Gas Recirculation Cooler Page 3 of 8
WARNING
Some solvents are
flammable and toxic. Read
the manufacturer's
instructions before using.
WARNING
Use skin and eye protection
when handling caustic
solutions to reduce the
possibility of personal injury.
WARNING
Wear appropriate eye and
face protection when using
compressed air. Flying
debris and dirt can cause
personal injury.
Use safety solvent to clean the
soot from the inside of the EGR
cooler.
Use compressed air to dry the
inside of the EGR cooler.
If any solvents or cleaners
entered the coolant side of the
EGR cooler, use fresh water to
flush the coolant side of the
cooler to prevent solvents and
cleaners entering the coolant.
Inspect the cooler for debris
and plugging.
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Exhaust Gas Recirculation Cooler Page 4 of 8
Install
Install the cooler and bracket
assembly to the cylinder
head, use two capscrews.
Tighten the capscrews.
Torque
Value: 33 n.m [24 ft-lb]
Finishing Steps
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Exhaust Gas Recirculation Cooler Page 5 of 8
WARNING
Coolant is toxic. Keep away
from children and pets. If not
reused, dispose of in
accordance with local
environmental regulations.
l Install the EGR valve
coolant return line. Refer
to Procedure 011-030
(EGR Valve Coolant
Lines) in Section 11.
l Install the EGR cooler
connection tube. Refer to
Procedure 011-024 (EGR
Cooler Connection) in
Section 11.
l Install the EGR
connection tube. Refer to
Procedure 011-025 (EGR
Connection Tubes) in
Section 11.
l Install the EGR cooler
coolant lines. Refer to
Procedure 011-031 (EGR
Cooler Connection) in
Section 11.
l Install the exhaust
pressure sensor tube.
Refer to Procedure 011-
027 (Exhaust Gas
Pressure Sensor Tube) in
Section 11.
l Fill the engine cooling
system. Refer to
Procedure 008-018
(Cooling System) in
Section 8.
Operate the engine and
check for boost/exhaust
coolant leaks.
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Exhaust Gas Recirculation Cooler Page 6 of 8
Test
Remove the EGR cooler
from the engine. Refer to the
Remove section of this
procedure.
Cap off one of the coolant
connections and connect a
regulated air supply hose to
the other coolant connection.
Place the EGR cooler into a
tank of heated water (60°C
[140°F]).
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The EGR cooler must be
completely submerged in the
water.
Apply air pressure of 310
kPa [45 psi].
Inspect for air bubbles
coming from the cooler.
Observe the cooler for a
minimum of 2 minutes under
water.
Verify that any air bubbles
are not a result of loose
connections or trapped air.
If the EGR cooler leaks, it
must be replaced.
Inspect the grid heater for
deposits and plugging if the
cooler was leaking internally.
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Exhaust Gas Recirculation Cooler Page 8 of 8
Last Modified: 07-Mar-2013
Copyright © 2000-2010 Cummins Inc. All rights reserved.
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