MBE 900 – Section 4.5 Front Connector Housing – EGR Engine

Section 4.5
Front Connector Housing – EGR Engine

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Section 4.5.1
Thermostat Housing Removal – EGR Engine

Remove the thermostat housing as follows( see Figure "Coolant Pump – EGR Engine" for component location):‪

1. Upper Thermostat Housing‪	5. Banjo Bolt‪
2. Lower Thermostat Housing‪	6. Coolant Pump‪
3. Connector Tube‪	7. Oil Filter‪
4. Air Compressor Coolant Line‪	8. Cab Heater Tube‪

Figure 1. Coolant Pump – EGR Engine

HOT COOLANT ‪
To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.‪

1. Drain engine coolant.
2. Remove the fan and fan shroud from the vehicle.
3. Release the tension on the poly-V belt and remove belt.
4. Remove the pulley mounting bolts and pulley.
5. Remove EGR delivery pipe. Refer to "10.9.1 EGR Delivery Pipe Removal" .
6. Remove EGR coolant inlet tube. Refer to "10.7.1 EGR Coolant Inlet Tube Removal" .
7. Remove EGR coolant return tube. Refer to "10.8.1 EGR Coolant Return Tube Removal" .
8. Remove charge air intake housing. Refer to "10.3.1 EGR Charge Air Intake Housing Removal" .
9. Remove engine trim panel.
10. Remove engine valve cover. Refer to "1.1.1 Cylinder Head Cover Removal" .
11. Remove three bolts securing heater supply tube (1). Remove tube and discard seal ring. See Figure "Coolant Pump – EGR Engine" .
12. Disconnect coolant temperature sensor connector from lower thermostat housing (2). If required remove temperature sensor (6) from housing. See Figure "Coolant Pump – EGR Engine" .
13. Remove two bolts securing thermostat housing and remove housing and gasket. Discard gasket.
14. Remove water connector tube (3) from lower thermostat housing (2) and discard tube. See Figure "Coolant Pump – EGR Engine" .
15. Remove three bolts securing upper thermostat housing (1) to lower thermostat housing (2) and remove cover. See Figure "Coolant Pump – EGR Engine" .
16. Remove thermostat(s) and O-ring(s) from thermostat housing. Discard O-rings.
17. Check thermostat(s). Refer to "4.6.1.1 Thermostat Checking" .

Section 4.5.2
Thermostat Housing Installation – EGR Engine

Install the thermostat housing as follows:‪

1. Install a new O-ring on each thermostat and install thermostats in lower housing.
2. Secure the thermostat upper housing (1) to lower thermostat housing (2) with three bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft). See Figure "Coolant Pump – EGR Engine" .
3. Install a new water connector tube (3) with seal in coolant pump (6). See Figure "Coolant Pump – EGR Engine" .
4. Install a new gasket and secure the thermostat housing (2) to the coolant pump (6) with two bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft).
5. Secure coolant inlet tube at clamp on thermostat with bolt. Tighten bolts to 31-35 N·m (23-26 lb·ft).
6. If removed, install temperature sensor in thermostat housing.
7. Position thermostat housing (2) over connector tube (3).
8. Install a new gasket and secure the thermostat housing (2) to the coolant pump (6) with two bolts. See Figure 5-4. Tighten bolts to 31-35 N·m (23-26 lb·ft).
9. Connect temperature sensor electrical connector at thermostat housing.
10. Install engine valve cover. Refer to "1.1.2 Cylinder Head Cover Installation" .
11. Install engine trim panel.
12. Install charge air intake housing. Refer to "10.3.2 EGR Charge Air Intake Housing Installation" .
13. Install EGR coolant return tube. Refer to "10.8.2 EGR Coolant Return Tube Installation" .
14. Install the EGR coolant inlet tube. Refer to "10.7.2 EGR Coolant Inlet Tube Installation" .
15. Install EGR delivery pipe. Refer to "10.9.2 EGR Delivery Pipe Installation" .
16. Install water pump pulley and secure with bolts Tighten bolts to 31-35 N·m (23-26 lb·ft).
17. Release the belt tensioner. Route the poly-V belt around the fan pulley and restore belt tension.
18. Install the fan blade and fan shroud on the vehicle. Position the fan shroud on the radiator and tighten the fan shroud mounting bolts until firm.
19. Fill the engine with removed coolant, and check for leaks. Refer to "10.5.2.1 Testing Engine for Leaks" .