Page 356
REPAIR INSTRUCTIONS, PART 1
6. Install the cab heater coolant return hose
and valve into the thermostat housing (if
applicable). Also install the optional fuel
heater coolant return hose into the
thermostat housing (if equipped). The cab
heater and optional fuel heater coolant
return hoses were relocated from the
thermostat housing to the radiator lower
tube in mid-2004.
7. Reconnect the bypass and radiator hoses at
the front of the thermostat housing
(Figure 426) and reconnect the surge tank
hose. Tighten all hose clamps to
specifications.
426
Figure 426 — Thermostat Housing Hose Connections
8. Refill the surge tank with the coolant
removed at disassembly.
EGR Mixer Tube Installation
[214 HL]
1. Clean and inspect the mating flange for the
EGR cool tube. Install a new graphite
wire-mesh seal in the flange.
2. Clean and inspect the mounting collar on the
inlet manifold. Then, install a new O-ring on
the collar (Figure 427).
427
Figure 427 — O-Ring Installation
3. Place the mixer tube in position on the inlet
manifold (Figure 428) and install the two
mounting capscrews. Tighten the capscrews
to specification, 40 lb-ft (55 N폷m).
428
Figure 428 — EGR Mixer Tube Installation
4. Install the capscrew attaching the support
bracket to the side of the mixer tube. Tighten
the capscrew to specification, 40 lb-ft
(55 N폷m).
1. Bypass Hose
2. Radiator Hose Port
3. Surge Tank Port
1. O-Ring 2. Inlet Manifold
1. EGR Mixer Tube 2. Inlet Manifold
5-111.bk Page 356 Monday, July 10, 2006 2:26 PM
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