EGR Cooler - Installation

CAB CHASSIS





1. If removed, install EGR cooler support bracket and tighten mounting bolts finger tight. If the EGR cooler support bracket was already installed, loosen the bolts to finger tight.
2. Using a new gasket, position EGR cooler (2) on exhaust manifold flange. Tighten flange nuts (1) to finger tight.






NOTE: Lubricate the new O-rings with a soapy water solution.

3. Install EGR Cooler mounting bolts (3) finger tight.
4. Using new O-rings, install the rear coolant tube to connection (4) then (1) and install the bolt (2) finger tight.





5. Tighten nuts (1) on the EGR cooler inlet flange to the exhaust manifold to 60 Nm (44 ft. lbs.).





6. Using a crisscross pattern, tighten bolt (2) and (3) to 24 Nm 18 ft. lbs.) to secure the EGR cooler onto the EGR cooler mounting bracket.





7. Tighten the EGR cooler mounting bracket to cylinder head bolts to 36 Nm (27 ft. lbs.).






NOTE: Lubricate the new O-rings with a soapy water solution.

8. Using a new O-ring (2), install the forward coolant tube (3) onto EGR cooler (1).





9. Install the breather tube (2) and connect breather hose (1), Tighten the bolt (3) 24 Nm (18 ft. lbs.).





10. Using new gasket, position EGR crossover tube (2) to EGR Cooler. Install clamp (1) finger tight.
11. Using new gasket, position EGR crossover tube (2) to EGR Valve (3). Install clamp (1) finger tight.
12. Tighten clamps (1 and 3) to 10 Nm (89 in. lbs.).
13. Install clamp (5). Tighten clamp to 10 Nm (89 in. lbs.).
14. Connect EGR valve electrical connector (4).










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16. Install the outlet tube (2) to the turbocharger and tighten the clamp (1) to 11 Nm (97 in. lbs.).
17. Connect the breather hose (3).





18. Install the air cleaner assembly Air Cleaner Body - Installation.





19. Install engine cover and tighten bolts (1) to 10 Nm (89 in. lbs.).
20. Connect both negative battery cable.
21. Fill cooling systemService and Repair.

CAUTION: When install the EGR Cooler it is necessary to bleed the system twice to ensure there is no trapped air in the EGR cooler. Failure to heed this caution may result in EGR cooler failure.

22. Start engine and check for coolant or exhaust leaks.