ISM, ISMe, and QSM11 – 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 a malfunction that allows coolant to leak into the EGR differential pressure sensor tubes, the tubes must be replaced.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the exhaust gas pressure sensor tube. Refer to Procedure 011-027 in Section 11.
• Remove the exhaust gas recirculation cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Remove the EGR differential pressure sensor tubes. Refer to Procedure 011-026 in Section 11.
• Remove the EGR connection tube. Refer to Procedure 011-025 in Section 11.
• Remove the EGR mixer. Refer to Procedure 011-021 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 any loose dirt from the vicinity of the air handling connections to avoid contamination of the interior of the engine.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the exhaust gas recirculation cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Remove the EGR differential pressure sensor tubes. Refer to Procedure 011-026 in Section 11.
• Remove the EGR connection tube and EGR venturi tube. Refer to Procedure 011-025 in Section 11.
• Remove the EGR mixer. Refer to Procedure 011-021 in Section 11.
• Remove the aftertreatment fuel injector coolant return line. Refer to Procedure 011-051 in Section 11.
• Remove the turbocharger coolant return line. Refer to Procedure 010-041 in Section 10.

Loosen the V-band clamp between the EGR cooler and the EGR valve. When removing the V-band clamp, do not damage the EGR connection tube.

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

Remove the five capscrews that attach the EGR cooler to the intake manifold.

Remove the EGR cooler assembly from the engine.

Loosen the v-band clamp between the EGR cooler and the exhaust manifold.

To prevent damage to the EGR cooler bellows, place the v-band clamp over the exhaust manifold flange.

Remove the five capscrews that attach the EGR cooler to the intake manifold.

Remove the EGR cooler assembly from the engine.

After removal, cover all open points with the appropriate protective caps from the Air Handling Clean Care Kit, Part Number 4919403, or with heavy tape, if needed.

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 service kit, Part Number 3164843.

Completely fill the EGR cooler with safety solvent.

Cap the gas inlet end of the EGR cooler with parts supplied in service kit, Part Number 3164843.

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.

Properly dispose of the liquid.

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 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.

The EGR cooler can be cleaned again if necessary, although one cleaning is usually enough.

Cap the outlet end of the EGR cooler with parts supplied in service kit, Part Number 3164843.

Completely fill the EGR cooler with water.

Cap the gas inlet end of the EGR cooler with parts supplied in service kit, Part Number 3164843.

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 mates 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. Refer to Procedure 011-025 in Section 11.

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

Inspect the EGR cooler connection. Replace the EGR cooler connection if cracks or other damage is found. Refer to Procedure 011-025 in Section 11.

Inspect the V-band clamps for signs of over-extension. The band must not be bent or cracked.

Inspect the V-band clamp threads for damage.

Replace the V-band clamp if damage is found.

Inspect the EGR cooler bellows for cracks or other damage.

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

Inspect the v-band clamp threads for damage. Replace the v-band clamp 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.

CAUTION  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.

Install the plastic cap over the pipe coupling and coolant outlet and secure with a hose clamp, supplied in the service kit, Part Number 4919424.

Completely fill the EGR cooler with safety solvent.

Install the threaded plugs (1) into the coolant line port and vent of the EGR cooler, supplied in service kit, Part Number 4919424.

Install the plug with the o-ring into the coolant inlet side of the EGR cooler.

Install the capscrew.

Install the cap (1), clamp (2), and strap (3) onto the coolant outlet and coolant outlet coupling of the EGR cooler.

Install the capscrew.

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.

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.

Properly dispose of the liquid.

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 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.

The EGR cooler can be cleaned again if necessary, although one cleaning is usually enough.

Cap the outlet end of the EGR cooler with parts supplied in service kit, Part Number 4919424.

Completely fill the EGR cooler with water.

Install the plastic cap over the coolant outlet and secure with the hose clamp supplied in service kit, Part Number 4919424.

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 EGR valve with safety solvent where the EGR cooler connection mates to the EGR valve and the exhaust manifold. Refer to Procedure 011-022 in Section 11.

Inspect the EGR valve where the EGR cooler connection mates to the EGR valve and the exhaust manifold. Replace the EGR valve or the exhaust manifold front section if cracks or other damage is found. Refer to Procedure 011-022 in Section 11. Refer to Procedure 011-007 in Section 11.

Inspect the v-band clamps for signs of over-extension. The band must not be bent or cracked.

Inspect the v-band clamp threads for damage.

Replace the v-band clamp if damage is found.

After the parts are clean and dry, cover all open points with protective caps from the Air Handling Clean Care Kit, Part Number 4919403, or with heavy tape, if needed.

Cap the coolant inlet and vents of the cooler with the parts supplied in service kit, Part Number 3164843.

Cap the coolant outlet with the plugged jumper tube and pressure regulator assembly. Jumper tube, Part Number 3683068, from the cooler is also used.

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 EGR cooler connection 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.

NOTE: Bubbles coming from a damaged EGR cooler will be very small or will not be a steady stream.

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

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

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 Turbocharger (VGT) Operational Test with INSITE™ electronic service tool to make sure of proper operation of the turbocharger. Coolant deposits can be identified as dried white deposits coating the inside of the turbine housing.

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

Make sure the pressure regulator is closed.

Disconnect the air pressure from the EGR cooler assembly.

Carefully vent the trapped air from the EGR cooler assembly.

Remove the test fittings.

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

Dry the cooler with compressed air.

Clean the EGR cooler using the steps found in the Clean and Inspect for Reuse section of this procedure, if not already completed.

Install the threaded plugs (1) into the coolant line port and vent of the EGR cooler. The plugs are supplied in service kit, Part Number 4919424.

Install the plug with the o-ring into the coolant inlet side of the EGR cooler.

Install the capscrew.

Install the cap (1), clamp (2), and strap (3) from service kit, Part Number 4919424, onto the coolant outlet and coolant outlet coupling of the EGR cooler.

Install the capscrew.

NOTE: Use the steps found in the Clean and Inspect for Reuse section to clean the EGR cooler.

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 EGR cooler connection 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.

NOTE: Bubbles coming from a damaged EGR cooler will be very small or will not be a steady stream.

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

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

If the EGR cooler is not usable, inspect the turbocharger turbine housing and EGR valve inlet for any signs of coolant deposits. Coolant deposits can be identified as dried white deposits coating the inside of the turbine housing.

If the EGR cooler is not reusable, replace the crankcase breather element. Refer to Procedure 003-019 in Section 3.

If coolant deposits are found, inspect the turbocharger for progressive damage. Coolant can cause the turbocharger to stick. Use the following procedure for inspection guideines. Refer to Procedure 010-033 in Section 10.

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

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

Remove the EGR valve and inspect for reuse. Refer to Procedure 011-022 in Section 11.

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

Make sure the aire pressure regulator is closed.

Disconnect the air pressure from the EGR cooler assembly.

Carefully vent the trapped air from the EGR cooler assembly.

Remove the test fittings.

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

Dry the cooler with compressed air.

After testing is completed and parts are dry, cover all open points with protective caps from the Air Handling Clean Care Kit, Part Number 4919403, or with heavy tape, if needed.

Loosely install the bottom two mounting capscrews and install the EGR cooler onto them.

Install the top three capscrews and tighten all five capscrews.

Install a new EGR cooler connection gasket with the adhesive side on the piloted end of the EGR cooler connection, where it connects with the EGR valve.

Before installing the V-band clamp, coat the clamping surface with high temperature anti-seize compound.

Install the V-band clamps between the EGR valve and EGR cooler connection.

Tighten the V-band clamp between the EGR cooler connection and the EGR valve.

Remove any protective caps or heavy tape.

Loosely install the bottom two mounting capscrews and install the EGR cooler onto them.

Install the top three capscrews and tighten all five capscrews.

Install new EGR cooler connection gaskets with the adhesive side on the piloted end of each joint.

Before installing the V-band clamp, coat the clamping surface with high temperature anti-seize compound.

Install the v-band clamps between the EGR valve and EGR cooler.

Tighten the v-band clamps.

• Install the EGR mixer. Refer to Procedure 011-021 in Section 11.
• Install the EGR connection tube. Refer to Procedure 011-025 in Section 11.
• Install the EGR differential pressure sensor tubes. Refer to Procedure 011-026 in Section 11.
• Install the exhaust gas pressure sensor tube. Refer to Procedure 011-027 in Section 11.
• Install the EGR cooler connection heat shield. Refer to Procedure 011-032 in Section 11.
• Install the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Fill engine cooling system. Refer to Procedure 008-018 in Section 8.
• Start the engine, check for leaks, and verify proper operation.

• Install the turbocharger aftertreatment injector lines. Refer to Procedure 011-051 in Section 11.
• Install the turbocharger coolant return line. Refer to Procedure 010-041 in Section 10.
• Install the EGR mixer. Refer to Procedure 011-021 in Section 11.
• Install the EGR connection tube and EGR venturi tube. Refer to Procedure 011-025 in Section 11.
• Install the EGR differential pressure sensor tubes. Refer to Procedure 011-026 in Section 11.
• Install the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Start the engine, check for leaks, and verify proper operation.

NOTE: If a malfunction resulted in oil, excessive fuel, or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Consult 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.