Series 60 – Section 8.4 EGR Rate Measurement System

Section 8.4
EGR Rate Measurement System

The EGR Rate Measurement system provides DDEC with measurements resulting in EGR flow rate prediction. The EGR Rate Measurement system consists of a venturi tube with a Delta P Sensor and a Exhaust Gas Temperature Sensor. Pressure differential between the venturi tube inlet, throat and along with exhaust gas temperature are converted to mass flow rate in DDEC. The venturi tube is a component of the delivery pipe.‪

Section 8.4.1
Removal of EGR Rate Measurement System

Removal steps are as follows:‪

PERSONAL INJURY ‪
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component.‪

1. Remove connector at Delta P sensor.
2. Remove the four hose clamps (4) securing the Delta P tubes (5 and 9) to the Delta P Sensor bracket (11). See Figure "Delta P Sensor and Related Parts" .
   

   1. Delta P Sensor‪	6. Delta P Tube Fittings‪	10. Nut‪
   2. Stud‪	7. Venturi Tube‪	11. Bracket‪
   3. Isolator‪	8. P-Clips‪	12. Thermostat Housing‪
   4. Hose Clamp‪	9. Delta P Tube‪	13. Bolt‪
   5. Delta P Tube‪	‪	‪

   Figure 1. Delta P Sensor and Related Parts

3. Remove the two bolts securing the P-clips (8) and Delta P tubes (5 and 9) to the exhaust manifold heat shield. See Figure "Delta P Sensor and Related Parts" .
4. Loosen and disconnect the Delta P tube fittings (6) from the venturi tube (7). See Figure "Delta P Sensor and Related Parts" .
5. Remove the Delta P tubes (5 and9) from the hoses securing them to the sensor mounting bracket (11). See Figure "Delta P Sensor and Related Parts" .
6. Remove two bolts (13) securing the Delta P Sensor (1) to bracket (11). See Figure "Delta P Sensor and Related Parts" . Remove the Delta P Sensor.
7. Remove the three nuts (10) and six isolators (3) securing bracket (11) to thermostat housing. See Figure "Delta P Sensor and Related Parts" . Remove the bracket.

Section 8.4.1.1
Inspection and Testing of EGR Rate Measurement System

Inspection steps are as follows:‪

1. The Delta P DDEC IV sensor using the Key On Engine Off test method. Refer to the Series 60 Exhaust Gas Recirculation (EGR) Technicians Guide 7SE60. for the test method.
   1. If the sensor was diagnosed as defective, replace the sensor.
   2. If the sensor was diagnosed to not be defective, reuse the sensor.
2. The Delta P DDEC V sensor using the Key On Engine Off test method. Refer to the Series 60 Exhaust Gas Recirculation (EGR) Technicians Guide 7SE60. for the test method.
   1. If the sensor was diagnosed as defective, replace the sensor.
   2. If the sensor was not defective, reuse the sensor.
3. Visually inspect the isolators for damage.
   1. If any of the isolators are damaged, replace as necessary.
   2. If the isolators are not damaged, reuse the components for installation.
4. Visually inspect the Delta P tubes for damage.
   1. If any of the tubes are damaged, replace as necessary.
   2. If the tubes are not damaged, reuse the components for installation.

Section 8.4.2
Installation of EGR Rate Measurement System

Installation steps are as follows:‪

1. Install three isolators (3) over studs (2) of thermostat housing (12). See Figure "Delta P Sensor and Related Parts" .
2. Install bracket (11) onto the thermostat housing (12). See Figure "Delta P Sensor and Related Parts" .
   

   1. Delta P Sensor‪	6. Fitting Nut‪	10. Nut‪
   2. Stud‪	7. Venturi Tube‪	11. Bracket‪
   3. Isolator‪	8. Clip‪	12. Thermostat Housing‪
   4. Hose Clamp‪	9. Delta P Tube‪	13. Bolt‪
   5. Delta P Tube‪	‪	‪

   Figure 2. Delta P Sensor and Related Parts

3. Install remaining three isolators (3) over studs (2) and secure bracket (11) and isolators (3) to the thermostat housing with nuts.See Figure "Delta P Sensor and Related Parts" . Torque nuts to 23-27 N·m (17-20 lb·ft).
4. Install the Delta P Sensor (1) to bracket (11) and secure with bolts (13). See Figure "Delta P Sensor and Related Parts" . Torque bolts to 30-38 N·m (22-28 lb·ft).
5. Install the hose clamps (4) to the Delta P Sensor bracket (11). See Figure "Delta P Sensor and Related Parts" .
6. Insert the Delta P tubes (5 and 9) to the hoses and secure with hose clamps (4). See Figure "Delta P Sensor and Related Parts" .
7. Connect the Delta P tubes (5 and 9) to the venturi tube (7). See Figure "Delta P Sensor and Related Parts" .
8. Secure the P-clips (8) to the exhaust manifold and secure with bolts. See Figure "Delta P Sensor and Related Parts" . Torque the bolts to 30-38 N·m (22-28 lb·ft).
9. Torque Delta P tube fitting nuts (6) to 24-30 N·m (18-22 lb·ft). Connect Delta P sensor connector at sensor.