EGR COOL ER AND TUBING 111
Installation
1. Clean port in rear half of front cover which EGR
cooler supply tube fits into.
CAUTION: To prevent engine damage, do not
use engine oil or any other petroleum based
products on EGR cooler supply tube O-rings.
These O-rings are not compatible with petroleum
based lubricants.
2. Install new O-ring seals on EGR cooler supply
tube assembly ends and reinstall tube into port in
rear half of front cover.
3. Install new EGR hot side gasket on new EGR
cooler.
4. Position EGR cooler on the engine and install
two new EGR rear mounting bolts. Finger tighten
bolts.
5. Reinstall EGR cooler mounting bracket lower bolt
and finger tighten.
6. Push EGR cooler supply tube assembly into EGR
cooler and finger tighten retaining bolt.
7. Install new EGR tube to EGR valve gasket and
finger tighten three bolts holding EGR tube to
EGR cooler.
8. Tighten EGR rear mounting bolts (M8 x 30) to
the standard torque (General Torque Guidelines,
page445).
9. Tighten EGR cooler mounting bracket lower bolt
(M12 x 120) to the special torque (Table 10).
10. Tighten EGR cooler mounting bracket to the
special torque (Table 10).
11. Tighten three bolts (M8 x 25) holding EGR tube
assembly to EGR cooler to the standard torque
(General Torque Guidelines, page445).
12. Tighten EGR cooler supply tube retaining bolt (M8
x 16) to the special torque (Table 10).
13. Push EGR return hose onto EGR cooler and
tighten constant tension EGR hose clamps to the
special torque value (Table 10).
14. Push deaeration hose onto EGR cooler
deaeration fitting and tighten clamp.
15. Refill engine cooling system.
16. Start engine and let engine warm up to operating
temperature.
17. Shut down engine and let engine cool to ambient
air temperature.
18. Retighten constant tension EGR hose clamps to
thespecialtorquevalue(Table10).
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
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