ISM, ISMe, and QSM11 – 011-031   EGR Cooler Coolant Lines

CAUTION  Do not use petroleum products on the coolant plumbing o-rings. The o-rings will swell and cause the connection to leak if petroleum products are used.

Lubricate the o-ring connection mating surfaces with clean engine coolant, soapy water, or vegetable oil. To avoid pinching or rolling the o-rings during assembly, do not lubricate the o-ring.

Install new o-rings on the EGR cooler coolant return tube and jumper connection.

Install the EGR cooler coolant return jumper connection into the EGR cooler coolant return tube.

Position the lower end of the EGR cooler coolant return tube jumper connection as illustrated in the graphic.

Install the EGR cooler coolant return tube from the water header plate to the EGR cooler coolant jumper connection.

Coat the EGR cooler coolant return tube mounting capscrew with high temperature anti-seize compound.

Install and tighten the capscrew.

Lubricate the o-ring connection mating surfaces with clean engine coolant, soapy water, or vegetable oil. To avoid pinching or rolling the o-rings during assembly, do not lubricate the o-ring.

Install new o-rings on the EGR cooler coolant supply upper tube.

Do not lubricate the retainer o-ring. Install the retainer o-ring (dry) onto the EGR cooler coolant supply upper tube past the small o-ring gland.

Install the EGR cooler coolant supply upper tube from the EGR cooler to the EGR cooler coolant supply lower tube and the EGR cooler coolant supply hose.

Install the EGR cooler coolant supply upper tube into the EGR cooler flange. Push the retainer o-ring up the EGR cooler coolant supply tube unit it contacts the EGR cooler flange.

Install the tube retainers and hose clamp onto the EGR cooler coolant supply upper tube, EGR cooler and retainer o-ring.

Tighten the hose clamp.

Tighten the EGR cooler coolant supply upper tube and water manifold return tube mounting capscrew (1).

Equally space the EGR cooler coolant supply hose over the EGR cooler coolant supply upper and lower tubes and tighten the hose clamps (2).

Lubricate the grommets with clean engine coolant, soapy water, or vegetable oil for easier installation and to avoid pinching or rolling the grommets while assembling.

Install the EGR cooler coolant front and rear vent tubes.

Install the retaining clip and capscrew for the EGR cooler coolant rear vent tube and tighten the capscrew.

CAUTION  Do not use petroleum products on the coolant plumbing o-rings. The o-rings will swell and cause the connection to leak if petroleum products are used.

Lubricate the o-ring connection mating surfaces with clean engine coolant, soapy water, or vegetable oil. To avoid pinching or rolling the o-rings during assembly, do not lubricate the o-ring.

Install new o-rings on the EGR cooler coolant return tube and jumper connection.

Install the EGR cooler coolant return jumper connection into the EGR cooler coolant return tube.

Position the lower end of the EGR cooler coolant return tube jumper connection as illustrated in the graphic.

Install the EGR cooler coolant return tube from the water header plate to the EGR cooler coolant jumper connection.

Coat the EGR cooler coolant return tube mounting capscrew with high temperature anti-seize compound.

Install and tighten the capscrew.

Lubricate the o-ring connection mating surfaces with clean engine coolant, soapy water, or vegetable oil. To avoid pinching or rolling the o-rings during assembly, do not lubricate the o-ring.

Install new o-rings on the EGR cooler coolant supply tube.

Install the EGR cooler coolant supply tube into the EGR cooler and the water pump.

Install the EGR cooler coolant supply tube capscrew into the EGR cooler coolant inlet flange. Do not torque.

Make sure the EGR cooler coolant supply tube is seated completely in the water pump body before tightening the EGR cooler coolant supply tube retaining clamp capscrew to reduce the possibility of pinching the o-ring.

Tighten the remaining clamp capscrew.

Tighten the EGR cooler coolant supply tube upper mounting capscrew.

Lubricate the grommets with clean engine coolant, soapy water, or vegetable oil for easier installation and to avoid pinching or rolling the grommets while assembling.

Install the EGR cooler coolant vent tube.