EGR Cooler - Installation

P/U





1. Install EGR cooler support bracket, if removed 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.





3. Using a new gasket, install the exhaust transfer manifold (3) Tighten nuts (4) to finger tight.
4. Using a new gasket, install the clamp (2) securing the EGR cooler (1) to exhaust transfer manifold (3), make sure that the bellows pilot is centered in the EGR cooler outlet. Tighten clamp finger tight.






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

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





7. If equipped, position back the transmission fill tube (2) to the EGR cooler (1) finger tight.





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





9. 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.





10. 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.

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





12. Tighten nuts (4) on the exhaust transfer manifold (3) to 43 Nm (18 ft. lbs.).
13. Tighten clamp (2) to 10 Nm (89 in. lbs.).





14. If equipped, tighten the nut (1) on the transmission fill tube (2) 10 Nm (89 in. lbs.).




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





16. Install the EGR cooler bypass valve Exhaust Gas Recirculation (EGR) Cooler Bypass Valve - Installation.










17. Install the generator Generator - Installation.





18. Install the outlet tube (2) to the turbocharger and tighten the clamp (1) 11 Nm (95 in. lbs.).
19. Connect the breather hose (3).





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





21. Install engine cover and tighten bolts (1) to 10 Nm (89 in. lbs.).
22. Connect negative battery cable(s).
23. Fill coolant system Service and Repair.
24. Start engine and check for coolant or exhaust leaks.