Series 60 – Section 8.2 Hydraulic EGR Valve

Section 8.2
Hydraulic EGR Valve

The EGR valve position is controlled by DDEC. The ECU continuously monitors all engine operation modes and performs self diagnostic checks of RPM, load, altitude, air temperature, etc. and uses this information to determine the valve position.‪

When the EGR valve is closed, exhaust gas will flow from the exhaust manifold and through the turbine wheel in the turbocharger, and out the exhaust system. When the EGR valve is open, some of the exhaust gas is directed into the EGR cooler, through the delivery pipe, and into the intake manifold.‪

Section 8.2.1
Removal of Hydraulic EGR Valve

Removal steps are as follows:‪

1. Loosen the one clamp (3) securing the bellow (10) to the EGR valve assembly (11). See Figure "Tube and Shell Bolted Flange EGR Cooler and Related Parts" .
   

   1. TSBF EGR Cooler‪	7. Exhaust Manifold End Section‪
   2 .EGR Hydraulic and Pneumatic Actuator Assembly‪	8. Exhaust Manifold Center Section‪
   3 Clamp‪	9. Exhaust Manifold End Section‪
   4.Upper Hot Pipe‪	10.Bellow‪
   5.Gasket‪	11.EGR Valve Assembly‪
   6.Stud‪	12.Gasket‪

   Figure 1. Tube and Shell Bolted Flange EGR Cooler and Related Parts

2. Remove the oil inlet fitting (3) and the oil outlet fitting (2) from the EGR valve and hydraulic actuator assembly (1). See Figure "EGR Valve and Hydraulic Actuator" .
   

   1. EGR Valve and Hydraulic Actuator Assembly‪	3. Oil Inlet Line and Fitting‪
   2. Oil Outlet Line and Fitting‪

   Figure 2. EGR Valve and Hydraulic Actuator

3. Remove the three nuts (1) from the studs (4) that secure the EGR valve and actuator assembly (2) to the cooler (5). See Figure "EGR Valve Assembly and Related Parts" .
   

   1. Nut‪	4. Stud‪
   2. EGR Valve and Actuator Assembly‪	5. TSBF EGR Cooler‪
   3. Gasket‪

   Figure 3. EGR Valve Assembly and Related Parts

4. Remove the EGR assembly (2) and gasket (3). Discard the gasket. See Figure "EGR Valve Assembly and Related Parts" .

Section 8.2.2
Disassembly of Hydraulic EGR Valve Assembly

Disassembly steps are as follows:‪

NOTICE: ‪

The actuator assembly can be separated from the EGR valve assembly. DO NOT disassemble the actuator or EGR valve assemblies. ‪

1. Remove the bolts (6) that secure the hydraulic actuator assembly (5) to the EGR valve assembly (1). See Figure "EGR Hydraulic Actuator and Related Parts" .
   

   1. EGR Valve Assembly‪	4. Splined Internal Drive‪	6. Bolts‪
   2. Insulator Shield‪	5. Hydraulic Actuator Assembly‪	7. Splined External Shaft‪
   3. Heat Shield‪	‪	‪

   Figure 4. EGR Hydraulic Actuator and Related Parts

2. Remove the hydraulic actuator assembly (5), heat shield (3), and insulator shield (2) from the EGR valve assembly (1). See Figure "EGR Hydraulic Actuator and Related Parts" .

   NOTICE: ‪

   The insulator cannot be reused and should be replaced whenever the hydraulic actuator is removed from the EGR valve assembly. Reuse of the insulator shield will damage the EGR assembly.‪

3. Discard the insulator shield (2). See Figure "EGR Hydraulic Actuator and Related Parts" .

Section 8.2.2.1
Cleaning of Hydraulic EGR Valve Spline Drive and Actuator Assembly

Cleaning steps are as follows:‪

1. Use a wire brush to remove debris and dirt from the splined internal drive (4) and splined external shaft (7). See Figure "EGR Hydraulic Actuator and Related Parts" .

   EYE INJURY ‪
   To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.‪

2. Use compressed air to remove dirt and debris from splined internal drive (4) and splined external shaft (7). See Figure "EGR Hydraulic Actuator and Related Parts" .

Section 8.2.2.2
Inspection of Hydraulic EGR Valve Spline Drive and Actuator Assembly

Inspection steps are as follows:‪

1. Visually inspect the hydraulic actuator assembly (5) for excessive wear and defects. See Figure "EGR Hydraulic Actuator and Related Parts" .
   1. If the actuator assembly is excessively worn or defective, replace the actuator assembly.
   2. If the actuator assembly is not excessively worn or defective, reuse the actuator assembly.
2. Visually inspect the EGR valve assembly (1) for excessive wear and defects. See Figure "EGR Hydraulic Actuator and Related Parts" .
   1. If the EGR valve is excessively worn or defective, replace the valve assembly.
   2. If the EGR valve is not excessively worn or defective, reuse the valve assembly.

Section 8.2.3
Assembly of Hydraulic EGR Valve Assembly

Assembly steps are as follows:‪

NOTICE: ‪

The insulator shield must be replaced whenever the actuator assembly has been removed from the EGR valve assembly. Reuse of the insulator shield will damage the EGR assembly.‪

NOTICE: ‪

The spline drive for the actuator assembly is keyed to ensure proper alignment with the shaft on the valve assembly. When performing step 1 , do not force any components onto the splined shaft. If excessive force is used, the splined shaft will be damaged.‪

1. Install the hydraulic actuator assembly (5), heat shield (3), and new insulator shield (2) onto the splined shaft (7) of the EGR valve assembly (1). See Figure "EGR Hydraulic Actuator and Related Parts" .
   

   1. EGR Valve Assembly‪	4. Splined Internal Drive‪	6. Bolts‪
   2. Insulator Shield‪	5. Hydraulic Actuator Assembly‪	7. Splined External Shaft‪
   3. Heat Shield‪	‪	‪

   Figure 5. EGR Hydraulic Actuator and Related Parts

   NOTICE: ‪

   When performing step 2 , apply torque evenly to the bolts to ensure that the EGR valve assembly and hydraulic actuator assembly are not misaligned. Misalignment will cause the assemblies to bind.‪

2. Install two bolts (6) through the hydraulic actuator assembly (5) to secure to the EGR valve assembly (1). Torque bolts (6) to 24-28 N·m (18-21 lb·ft).

Section 8.2.4
Installation of Hydraulic EGR Valve

Installation steps are as follows:‪

1. Place a new gasket (3) onto the EGR cooler (5). See Figure "EGR Valve Assembly and Related Parts" .
   

   1. Nut‪	4. Stud‪
   2. EGR Valve and Actuator Assembly‪	5. TSBF EGR Cooler‪
   3. Gasket‪

   Figure 6. EGR Valve Assembly and Related Parts

2. Properly align the EGR valve and actuator assembly (2) with studs (4) and install onto the EGR cooler (5). See Figure "EGR Valve Assembly and Related Parts" .

   Note: The EGR valve inlet tube should face the flywheel housing.

3. Secure the EGR valve and actuator assembly (2) to the EGR cooler (5) with nuts (1). Torque the nuts to 22-26 N·m (16-19 lb·ft). See Figure "EGR Valve Assembly and Related Parts" .
4. Install the oil inlet line fitting (3) and outlet line fitting (2) to EGR valve actuator. Torque fittings to 24-28 N·m (18-21 lb·ft). See Figure "EGR Valve Oil Inlet line and Oil Outlet Line" .
   

   1. EGR Valve and Hydraulic Actuator Assembly‪	3. Oil Inlet Line and Fitting‪
   2. Oil Outlet Line and Fitting‪

   Figure 7. EGR Valve Oil Inlet line and Oil Outlet Line

5. Install the EGR valve assembly (11) to bellow (10) and secure with clamp (3). Torque clamp (3) to 12 N·m (106 lb in). See Figure "Tube and Shell Bolted Flange EGR Cooler and Related Parts" .
   

   1. TSBF EGR Cooler‪	7. Exhaust Manifold End Section‪
   2. EGR Hydraulic or Pneumatic Actuator Assembly‪	8. Exhaust Manifold Center Section‪
   3. Clamp‪	9. Exhaust Manifold End Section‪
   4. Upper Hot Pipe‪	10.Bellow‪
   5. Gasket‪	11. EGR Valve Assembly‪
   6. Stud‪	12. Gasket‪

   Figure 8. Tube and Shell Bolted Flange EGR Cooler and Related Parts