Centinel System – Repair Manual – 011-031   EGR Cooler Coolant Lines

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.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the air intake piping. Refer to the OEM service manual. Use protective caps from the Air Handling Clean Care Kit, Part Number 4919425, to cover the connection points.
• Remove the exhaust gas pressure sensor tube. Refer to Procedure 011-027 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.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the air intake piping. Refer to the OEM service manual.  Use protective caps from the Air Handling Clean Care Kit, Part Number 4919425, to cover the connection points.

Disconnect the EGR cooler coolant vent line from the EGR cooler coolant return line and the EGR cooler.

Remove the two mounting capscrews from the EGR cooler coolant return line.

Disconnect the EGR cooler coolant return line from the EGR cooler and the elbow connection on the thermostat housing.

CAUTION  Be sure all the components are clean and free of debris that can cause damage to o-ring seals.

Disconnect the EGR cooler coolant vent line from the thermostat housing and the EGR cooler.

Remove the two EGR cooler coolant return tube mounting capscrews.

Remove the EGR cooler coolant return jumper tube from the EGR cooler.

Remove the EGR cooler coolant supply tube mounting capscrew.

Slide the EGR cooler coolant supply jumper tube all the way rearward inside the EGR cooler coolant supply tube.

Remove the EGR cooler coolant supply tube retaining clamp capscrew from the water pump housing.

Slide the EGR cooler coolant supply tube rearward until the EGR cooler coolant supply tube is disengaged from the water pump outlet.

Remove the EGR cooler coolant supply tube from the engine.

Remove and discard all three o-rings.

Remove the nuts from the EGR cooler coolant supply tube mounting bracket.

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 coolant vent and the EGR cooler coolant return line with solvent.

Dry with compressed air.

Inspect the EGR cooler coolant vent and the EGR cooler coolant return line for cracks or other damage. Replace the lines if cracked or otherwise damaged.

Inspect the EGR cooler vent line grommets for damage.

Replace the grommets if they are damaged.

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 coolant vent line and the EGR cooler coolant supply and return tubes with solvent.

Dry with compressed air.

Inspect the EGR cooler vent line grommets for damage.

Replace the grommets if they are damaged.

Inspect the EGR cooler for cracks or other damage. Replace the lines if cracked or otherwise damaged.

CAUTION  Do not use petroleum products on the EGR cooler coolant line o-rings. The o-rings will swell and cause the connection to leak.

Install new the o-rings on the EGR cooler coolant return line.

Lubricate the o-rings with clean engine coolant, soapy water, or vegetable oil for easier installation.

Install the EGR cooler coolant return line from the EGR cooler to the thermostat housing.

Tighten the mounting capscrews.

Install the EGR cooler coolant vent line. Attach the rigid section of the vent line to the EGR cooler and the flexible section to the EGR cooler coolant return line.

CAUTION  Do not use petroleum products on the EGR cooler coolant line o-rings. The o-rings will swell and cause the connection to leak.

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

Lubricate the o-rings with clean engine coolant, soapy water, or vegetable oil to aid in installation.

Install the EGR cooler coolant supply tube mounting bracket and nuts.

Tighten the nuts.

Insert the EGR cooler coolant supply jumper tube into the EGR cooler coolant supply tube.

Slide the EGR cooler coolant supply jumper tube into the EGR cooler inlet.

Install the retaining clamp and capscrew to the EGR cooler.

NOTE: Do not tighten at this time.

Insert the EGR cooler coolant supply tube into the water pump outlet.

Install the EGR cooler coolant supply tube retaining clamp and capscrew.

NOTE: Do not tighten at this time.

Tighten in the following sequence.

Install the EGR cooler coolant supply tube mounting capscrew and tighten.

Tighten the EGR cooler coolant supply jumper tube retaining clamp capscrew.

Tighten the EGR cooler coolant supply tube retaining clamp capscrew.

Install the EGR cooler coolant vent line to the thermostat housing and the EGR cooler.

Install the o-rings on the coolant return tube jumper tube.

Lubricate the o-rings with clean engine coolant, soapy water, or vegetable oil, for easier installation.

Install the jumper tube into the EGR cooler.

Install the press in place seal and the coolant return tube.

Install and tighten the capscrews.

• Install the exhaust gas pressure sensor tube. Refer to Procedure 011-027 in Section 11.
• Remove the protective caps from the intake piping.
• Install the air intake piping. Refer to the OEM service manual.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks. Check for leaks.

• Remove the protective caps from the intake piping.
• Install the intake piping. Refer to the OEM service manual.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks.