Centinel System – Repair Manual – 011-019   EGR Cooler

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

NOTE: If the EGR cooler is being replaced due to an internal coolant leak, the EGR differential pressure tubes must be replaced.

NOTE: Brush away all loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

NOTE: If the Exhaust Gas Recirculation (EGR) cooler is being replaced due to an internal coolant leak, the EGR differential pressure tubes must be replaced.

NOTE: Brush away all loose dirt from around the area of the air-handling connections to avoid contamination of the interior of the engine.

• Drain the engine coolant. Refer to Procedure 008-018 in Section 8.
• Remove the air intake pipe to turbocharger. Refer to the OEM service manual. Use protective caps from the Cummins® Vehicle Air Pumping Clean Care Kit, Part Number 4912425, to cover the connection points.
• Remove the charge-air cooler pipe between the turbocharger and charge-air cooler. Refer to the OEM service manual. Use protective caps from the Cummins® Vehicle Plumbing Clean Care Kit, Part Number 4919425, to cover the connection points.
• Remove the turbocharger. Refer to Procedure 010-033 in Section 10.
• Remove the exhaust gas pressure sensor tube. Refer to Procedure 011-027 in Section 11.
• Remove the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

NOTE: Brush away all loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

NOTE: If the EGR cooler is being replaced due to a malfunction that caused an internal coolant leak, the crankcase breather element must be replaced.

NOTE: If the EGR cooler is being replaced due to a malfunction that caused an internal coolant leak, the EGR differential pressure sensor tubes should be inspected for deposits.  If deposits are found, replace the EGR differential pressure tubes.

NOTE: If pressure testing the EGR cooler on ISX CM871 engines, do not remove the aftertreatment injector or turbocharger before pressure testing the EGR cooler.

• Drain the engine coolant. Refer to Procedure 008-018 in Section 8.
• Remove the air intake pipe to turbocharger. Refer to the OEM service manual. Use protective caps from the Cummins® Vehicle Air Plumbing Clean Care Kit, Part Number 4919425, to cover the connection points.
• Remove the charge-air cooler pipe between the turbocharger and charge-air cooler. Refer to the OEM service manual. Use protectve caps from the Cummins® Vehicle Plumbing Clean Care Kit, Part Number 4919425, to cover the connection points.
• Remove the aftertreatment adapter pipe and aftertreatment injector lines. Refer to Procedure 011-051 in Section 11. Refer to Procedure 011-043 in Section 11.
• Remove the turbocharger. Refer to Procedure 010-033 in Section 10.
• Remove the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.

Loosen the v-band clamp between the EGR cooler and the EGR cooler connection.

Loosen the hose clamps at the rear EGR connection tube.

Remove and discard the EGR hose.

CAUTION  The straps on the EGR cooler are not serviceable. Adjusting or removing the straps can damage the EGR cooler.

Remove the four capscrews that attach the EGR cooler to the block.

Remove the four nuts that attach the EGR cooler to the lubricating oil cooler assembly.

Remove the EGR cooler assembly from the engine.

Remove the coolant supply and vent jumper tubes if they remain in the block after the cooler is removed.

Loosen the v-band clamp between the EGR cooler and the exhaust manifold. In order to prevent damage to the EGR cooler bellows, place the v-band clamp over the exhaust manifold flange.

Loosen the rear EGR connection tube retaining capscrews at the EGR cooler gas outlet.

Remove and discard the gasket.

Use protective caps from the Air Handling Clean Care Kit, Part Number 4919403, to cover the open points on both the EGR cooler and EGR plumbing.

Remove the four capscrews that attach the EGR cooler to the block.

Remove the four nuts that attach the EGR cooler to the lubricating oil cooler assembly.

Remove the EGR cooler bracket clamping plates from the EGR cooler.

Remove the EGR cooler assembly from the engine.

Use protective caps from the Air Handling Clean Care Kit to cover the open ports on the EGR cooler and exhaust manifold.

Inspect the v-band clamp threads for damage. Replace the clamp if damage is found.

Inspect the hose clamps for damage. Replace if damage is found.

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.

Cap the outlet end of the EGR cooler with parts supplied in the EGR cooler leak check kit, Part Number 3164225.

Completely fill the EGR cooler with mineral spirits.

Cap the gas inlet end of the EGR cooler with parts supplied in the EGR cooler leak check kit, Part Number 3164225.

Lay the EGR cooler on its side.

Allow the EGR cooler to soak for approximately 20 minutes.

Drain approximately 25 percent of the liquid from the cooler and recap.

Shake the cooler by hand, from end to end, for approximately 30 seconds.

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.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Drain the mineral spirits from the EGR cooler and properly dispose of the liquid.

Use compressed air to dry the inside of the EGR cooler and remove any loose debris or particles.

Cap the outlet end of the EGR cooler with parts supplied in service kit, Part Number 3164225.

Completely fill the EGR cooler with water.

Cap the gas inlet end of the EGR cooler with parts supplied in service kit, Part Number 3164225.

Drain the water from the EGR cooler and properly dispose of the liquid.

Use compressed air to dry the inside of the EGR cooler.

Clean the EGR valve with safety solvent where the EGR cooler connection attaches to the EGR valve. Refer to Procedure 011-022 in Section 11.

Clean the EGR cooler connection with safety solvent and dry with compressed air.

Inspect the EGR valve where the EGR cooler connection attaches to the EGR valve. Replace the EGR valve if cracks or other damage is found. Refer to Procedure 011-022 in Section 11.

Replace the EGR cooler if cracks or other damage is found on the EGR cooler.

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.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

With the EGR connection tube attached, clean the cooler end of the EGR connection tube with safety solvent.

Dry with compressed air.

Inspect the EGR connection tube for cracks or other damage, while still attached to the block. Replace the EGR connection tube if necessary. Refer to Procedure 011-025 in Section 11.

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.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the EGR cooler connection with safety solvent and dry with compressed air.

Inspect the EGR cooler connection for cracks or other damage. Replace the EGR cooler connection if cracks or other damage is found. Refer to Procedure 011-024 in Section 11.

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.

Clean the mounting surfaces with safety solvent to remove any coolant deposits or debris.

Clean the opening in the block where the EGR cooler coolant supply and vent jumper tubes are installed to remove any coolant deposits or debris. Otherwise, the o-ring joint can leak.

Clean the coolant supply and vent jumper tubes to remove any coolant deposits or debris.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

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.

Inspect the v-band clamp threads for damage. Replace the clamp if damage is found.

Inspect the EGR cooler and the EGR cooler clamping plates for cracks or other damage. Replace the EGR cooler or EGR cooler clamping plates if cracks or other damage is found.

WARNING  Do not use chlorinated water to clean or rinse the EGR cooler. Chlorides are very corrosive to the stainless alloys internal and external to the EGR cooler.

Cap the outlet end of the EGR cooler with the plastic caps supplied in the service kit, Part Number 4918655.

Completely fill the EGR cooler with safety solvent.

Cap the gas inlet end of the EGR cooler with the plastic cap supplied in the service kit.

Lay the EGR cooler on its side.

Allow the EGR cooler to soak for approximately 20 minutes.

Drain approximately 25 percent of the liquid from the cooler and recap. Dispose of the liquid properly.

Shake the cooler by hand, from end to end, for approximately 30 seconds.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

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.

Drain the safety solvent from the EGR cooler and properly dispose of the liquid.

Use compressed air to dry the inside of the EGR cooler and remove any loose debris or particles.

Cap the outlet end of the EGR cooler with the plastic cap supplied in the service kit, Part Number 4918655.

Completely fill the EGR cooler with water.

Cap the gas inlet end of the EGR cooler with the plastic cap supplied in the service kit.

Shake the cooler by hand, from end to end, for approximately 30 seconds.

Drain the water from the EGR cooler and properly dispose of the liquid.

Use compressed air to dry the inside of the EGR cooler.

Clean the exhaust manifold with safety solvent, where the EGR cooler connection attaches to the exhaust manifold. Refer to Procedure 011-007 in Section 11.

Inspect the exhaust manifold where the EGR cooler connection attaches to the exhaust manifold. Replace the exhaust manifold if cracks or other damage is found. Refer to Procedure 011-007 in Section 11.

Replace the EGR cooler if cracks or other damage is found.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris or dirt can cause personal injury.

Clean the EGR cooler exhaust gas outlet with safety solvent.

Dry with compressed air.

Inspect the EGR cooler exhaust gas outlet for signs of fretting, cracks, or other damage.

Replace the EGR cooler if damage is found. Refer to Procedure 011-025 in Section 11.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

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.

Clean the EGR cooler bellows with safety solvent and dry with compressed air.

Inspect the EGR cooler bellows for cracks or other damage.

Replace the EGR cooler bellows if cracks or other damage is found.

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.

Clean the mounting surfaces with safety solvent to remove any coolant deposits or debris.

Clean the opening in the block where the EGR cooler coolant return elbow connection is installed, to remove any coolant deposits or debris. Otherwise, the press-in-place seal joint can leak.

Clean the EGR cooler coolant supply and return jumper tubes to remove any coolant deposits or debris.

Cap off the coolant inlet and vents of the cooler with the parts supplied in the EGR cooler leak check kit, Part Number 3164225. Jumper tube, Part Number 3683068, and jumper tube, Part Number 3682540, from the cooler, are also used.

Cap off the coolant outlet with the plugged jumper tube and pressure regulator assembly. Secure the jumper tube with a hose clamp.

Make sure the air pressure regulator is closed and connect compressed air to the pressure regulator.

Completely submerge the EGR cooler in room temperature water. Make sure to submerge the cooler vertically with the outlet end down so that air can not be left in the open (gas) side of the cooler.

Apply 206 kPa [30 psi] of air pressure to the cooler.

Inspect for bubbles escaping from uncapped gas ports of the EGR cooler or from the exterior shell of the cooler.

Verify that bubbles are not a result of loose fittings or trapped air.

Bubbles coming from a damaged EGR cooler can be very small and/or not in a steady stream.

If bubbles are not observed, the EGR cooler is reusable.

If the EGR cooler is not reusable, inspect the turbocharger turbine housing for any signs of coolant deposits.

If coolant deposits are found, run the variable geometry operational test with INSITE™ electronic service tool to make sure the turbocharger is operating properly.

Coolant deposits can be identified as dried white deposits coating the inside of the turbine housing.

Remove the parts supplied in the EGR cooler leak check kit, Part Number 3164225.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Drain all of the water from the gas side of the EGR cooler before reuse.

Dry the cooler with compressed air.

Install the plug with the o-ring supplied in Service Kit, Part Number 4918655, into the coolant inlet side of the EGR cooler, use a M8 x 1.25 capscrew.

Install the two straight threaded plugs (1) from Service Kit, Part Number 4918655, into the coolant line and vent ports.

Install the collet and cap over the pipe coupling and coolant outlet and secure with the hose clamp provided in Service Kit, Part Number 4918655.

NOTE: This step is necessary to prevent debris or moisture from entering the EGR piping or EGR valve.

Loosen the rear EGR connection tube retaining capscrews at the EGR cooler gas outlet.

Remove and discard the gasket.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

NOTE: Air pressure regulator kit, Part Number 3164231, or equivalent, is suitable for use during this step.

Install air pressure regulator and hose assembly onto the test fitting on the coolant inlet of the EGR cooler.

Install a ball type shutoff valve onto the inlet side of the air pressure regulator to allow the air supply to be shutoff during testing.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Make sure the air pressure regulator and ball-type valve are closed and connect compressed air supply to the pressure regulator.

Apply 620 kPa [90 psi] of air pressure to the EGR cooler.

Inspect for air escaping the EGR cooler assembly as a result of loose fittings by spraying the exterior of the EGR cooler and all lines and fittings with a mixture of mild soap and water.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Shut off the air supply to the regulator by using the ball-valve and disconnect the compressed air supply.

Record the time at which the air supply was shutoff and the air pressure shown on the air pressure regulator gauge.

Measure and record the air pressure after 15 minutes.

If the measured pressure loss in the EGR cooler is more than 35 kPa [5 psi] in 15 minutes, the EGR cooler is not reusable.

NOTE: If the EGR cooler is not reusable, inspect the air pressure regulator, air lines, ball-valve, o-rings and other components carefully for leaks.  A mixture of mild soap and water may be sprayed onto the assembly to aid in leak detection.

If the EGR cooler is not reusable, inspect the turbocharger turbine housing and rear EGR connection tube for any signs of coolant deposits.

Coolant deposits can be identified as dried white deposits coating the inside of the turbine housing.

If coolant deposits are found in the turbocharger turbine housing, inspect the turbocharger for progressive damage.

Coolant can cause the turbocharger to stick. Inspect the turboscharger for reuse. Refer to Procedure 010-033 in Section 10.

If coolant deposits are found in the rear EGR connection tube, inspect the EGR valve for progressive damage.

Coolant can cause the EGR valve to stick and allow coolant to collect.

Coolant deposits can be identified as dried white deposits coating the inside of the EGR valve passages.

If coolant deposits are found, remove the EGR valve and inspect for reuse. Refer to Procedure 011-022 in Section 11.

Install the parts supplied in the EGR cooler leak test kit:

• EGR Cooler Coolant Lines. Refer to Procedure 011-031 in Section 11.
• EGR Connection Tubes. Refer to Procedure 011-025 in Section 11.

Properly fill the cooling system. Refer to Procedure 008-018 in Section 8.

Install a new hose onto the rear EGR connection tube and install the hose clamps.

Install new o-rings on the coolant supply and vent tubes on the EGR cooler and the jumper tubes.

Use clean engine coolant, soapy water, or vegetable oil to lubricate the o-rings for easier installation.

Install the coolant supply and the vent jumper tubes onto the EGR cooler.

Align the coolant supply and vent tubes to the corresponding openings on the block.

Install the EGR cooler on the studs in the lubricating oil cooler assembly.

Install a new gasket on the pilot end of the EGR cooler where it connects to the EGR cooler connection.

Apply a film of high-temperature anti-seize compound to the inside of the v-band clamp, to make sure of proper loading on the clamp.

Install a v-band clamp.

Install and hand tighten the four mounting nuts and capscrews. Tighten the capscrews and nuts in the sequence shown.

Connect the EGR cooler to the new hose on the rear EGR connection tube.

Tighten the hose clamps.

Tighten the v-band clamp between the EGR cooler connection and the EGR cooler.

CAUTION  Keep all protective caps on the EGR cooler in place while grinding clearance in the upper mounting bracket. Failure to do so could cause progressive damage to the engine once the EGR cooler is installed. It’s important to prevent any debris from entering the cooler.

Inspect for an interference fit between the upper EGR cooler mounting bracket and the lower portion of the exhaust manifold flange. If this interference is present, grind a clearance on the upper EGR cooler mounting bracket in the area shown in the illustration.

Apply a film of high-temperature anti-seize compound to the inside of the v-band clamp, to make sure of proper loading on the clamp.

Install a v-band clamp onto the exhaust manifold front section.

Install a new gasket on the pilot end of the EGR cooler where it connects to the exhaust manifold front section.

Install the EGR cooler on the studs in the lubricating oil cooler assembly.

Install the EGR cooler bracket clamping plates.

Install the four EGR cooler mounting capscrews at the top of the EGR cooler mounting bracket.

Install and hand tighten the four mounting nuts. Tighten the capscrews and nuts in the sequence shown.

CAUTION  Do not use air tools to remove or install the nut on the v-band clamp. Use of these tools can seriously damage the threads or the bolt and cause the clamp to not be able to be reused.

Position the v-band clamp onto the EGR cooler inlet connection.

Tighten the two retaining capscrews on the rear EGR connection tube.

NOTE:  If the EGR cooler is being replaced due to an internal coolant leak, the EGR differential pressure tubes must be replaced.

• Install the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Install the exhaust gas pressure sensor tube. Refer to Procedure 011-027 in Section 11.
• Install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Remove the protective caps used to cover the charge-air cooler pipe connection points.
• Install the charge-air cooler pipe. Refer to the OEM service manual.
• Remove the protective caps used to cover the air intake pipe to the turbocharger
• Install the air intake pipe to the turbocharger. Refer to OEM service manual.
• Fill the engine cooling system. Refer to Procedure 008-018 in Section 8.
• Start the engine, check for leaks, and verify proper operation.

NOTE: If the EGR cooler is being replaced due to a malfunction that caused an internal coolant leak, the crankcase breather element must be replaced.

NOTE:  If the EGR cooler is being replaced due to a malfunction that caused an internal coolant leak, the EGR differential pressure sensor tubes should be inspected for deposits.  If deposits are found, replace the EGR differential pressure tubes.

NOTE: If a malfunction resulted in oil, excessive fuel, or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to the Aftertreatment Diesel Oxidation Catalyst and Aftertreatment Diesel Particulate Filter Reuse Guidelines, Bulletin 4021600.

NOTE: If a malfunction resulted in coolant entering the exhaust system, the aftertreatment system can be recovered. Refer to Procedure 014-013 in Section 14.

• Install the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Install the aftertreatment adapter pipe and aftertreatment injector lines. Refer to Procedure 011-043 and Refer to Procedure 011-051 in Section 11.
• Remove the protective caps used to cover the charge-air cooler pipe connection points.
• Install the charge-air cooler pipe. Refer to the OEM service manual.
• Remove the protective caps used to cover the air intake pipe connection points.
• Install the air intake pipe to the turbocharger. Refer to the OEM service manual.
• Fill the engine cooling system. Refer to Procedure 008-018 in Section 8.
• Start the engine, check for leaks, and verify proper operation.