MBE 900 – Section 10.5 EGR Cooler

Section 10.5
EGR Cooler

‪

Section 10.5.1
EGR Cooler Removal

Remove the EGR cooler as follows:‪

PERSONAL INJURY ‪
To avoid injury from scalding, drain the radiator when the engine and coolant are cool.‪

1. Drain the coolant.

   NOTICE: ‪

   No coolant must escape during disassembly of the coolant inlet line.‪

   

   1. EGR Delivery Pipe Bolts‪	6. Heat Shield‪
   2. EGR Delivery Pipe Gasket‪	7. Heat Shield Mounting bolts‪
   3. EGR Delivery Pipe‪	8. EGR Exhaust Elbow‪
   4. Bolts‪	9. EGR Exhaust Housing‪
   5. Bolts‪	‪

   Figure 1. EGR Cooler Removal and Installation

2. Remove the two bolts from the EGR delivery pipe. See Figure "EGR Cooler Removal and Installation" .
3. Remove four bolts from the EGR cooler upper flange. See Figure "EGR Cooler Removal and Installation" .
4. Remove EGR delivery pipe. See Figure "EGR Cooler Removal and Installation" .

   Note: The EGR cooler end gasket is a one piece gasket. Whenever the EGR delivery tube is removed, the EGR exhaust elbow must also be removed to replace the gasket. If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket.

5. Remove three bolts from heat shield and remove shield. See Figure "EGR Cooler Removal and Installation" .
6. Remove four bolts from the lower EGR cooler flange. Remove housing and elbow. See Figure "EGR Cooler Removal and Installation" .
7. Remove elbow from housing and inspect seal rings. If damaged replace seal rings. See Figure "EGR Cooler Removal and Installation" .
   

   1. Coolant Inlet Tube‪	5. Hose Clamps‪
   2. Coolant Return Tube‪	6. Bolts‪
   3. Clamps‪	7. Coolant Return Tube Clamp‪
   4. EGR Delivery Pipe‪	8. EGR Cooler‪

   Figure 2. Coolant Inlet Line and Related Components

8. Remove bolts from clamps securing coolant inlet tube to thermostat housing and air intake manifold. See Figure "Coolant Inlet Line and Related Components" .
9. Loosen two hose clamps from hose on coolant inlet tube.
10. Remove coolant inlet tube and O-ring. Discard O-ring.
11. Remove two bolts, hose and clamps securing EGR coolant return tube to thermostat housing and EGR cooler. See Figure "Coolant Inlet Line and Related Components" .
12. Remove EGR coolant return tube and gasket. Discard gasket.
13. Remove electrical plug connector from the EGR rotary valve. See Figure "EGR Rotary Valve and Related Components" .
14. Remove two bolts securing the EGR cooler. See Figure "EGR Rotary Valve and Related Components" .

    Note: On MBE 904, 906, 924 and 926 engines, the EGR cooler is secured with two brackets with two hose clamps.

    

    1. EGR Rotary Valve Electrical Connector‪	4. EGR Cooler‪
    2. EGR Rotary Valve‪	5. Clamps‪
    3. Bolts‪	‪

    Figure 3. EGR Rotary Valve and Related Components

15. Remove the hose clamps on the EGR cooler. See Figure "EGR Rotary Valve and Related Components" .
16. Remove the EGR cooler with the EGR rotary valve still attached. See Figure "EGR Rotary Valve and Related Components" .
17. If required, remove two EGR cooler lower support brackets by removing two bolts per bracket.
18. Remove the EGR rotary valve from the EGR cooler by removing five nuts and gasket. Discard gasket. See Figure "EGR Rotary Valve and Related Components" .

Section 10.5.2
EGR Cooler Installation

Install the EGR cooler as follows (see Figure "EGR Rotary Valve and Related Components" for component location):‪

1. Install the EGR rotary valve and new gasket on the EGR cooler with five nuts. Tighten nuts to 31-35 N·m (23-26 lb·ft).
2. If removed, install two lower EGR cooler support brackets and secure with two bolts per bracket. Tighten bolts to 60-66 N·m (44-49 lb·ft).
3. Install the EGR cooler on lower support brackets.
4. Secure EGR cooler with two bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft).
5. Install and tighten clamps on the EGR cooler.
6. Install electrical plug connector to the rotary valve. See Figure "EGR Rotary Valve and Related Components" .
7. Inspect the coolant return hose for any damage. Replace hose if required. Install the coolant return tube in hose. Using a new gasket and two bolts secure to the thermostat housing. Tighten bolts to 31-35 N·m (23-26 lb·ft). See Figure "Coolant Inlet Line and Related Components" .
8. Tighten hose clamps on coolant hose.
9. Install new seal ring on coolant inlet tube. See Figure "Coolant Inlet Line and Related Components" .
10. Install coolant inlet tube into hose and secure coolant inlet tube with two bolts at clamps. Tighten bolts to 31-35 N·m (23-26 lb·ft). See Figure "Coolant Inlet Line and Related Components" .
11. Install EGR exhaust elbow with seal rings in EGR exhaust housing and into end of exhaust manifold. See Figure "EGR Cooler Removal and Installation" .

    Note: The EGR cooler end gasket is a one piece gasket. Whenever the EGR delivery tube is removed, the EGR exhaust elbow must also be removed to replace the gasket. If the EGR exhaust elbow is removed the EGR delivery tube must be removed in order to replace the gasket.

12. Using a new gasket, install the EGR exhaust housing using four bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft). See Figure "EGR Cooler Removal and Installation" .
13. Install heat shield using three mounting bolts. Tighten bolts to 12-14 N·m (9-10 lb·ft). See Figure "EGR Cooler Removal and Installation" .
14. Loosely install EGR delivery pipe at upper cooler flange with four bolts. See Figure "EGR Cooler Removal and Installation" .
15. Install the EGR delivery pipe using a new gasket and two bolts. Tighten bolts to 31-35 N·m (23-26 lb·ft). See Figure "EGR Cooler Removal and Installation" .
16. Tighten EGR delivery pipe bolts at lower flange. Tighten bolts to 31-35 N·m (23-26 lb·ft). See Figure "EGR Cooler Removal and Installation" .
17. Fill engine with fresh coolant to required levels.

Section 10.5.2.1
Testing Engine for Leaks

Perform the following steps to test the engine for coolant leaks:‪

1. Check the coolant level and top off if required.
2. Check for leaks with the engine running.
3. If any leaks are observed shut engine down and make necessary repairs.