112 EGR COOLER AND TUBING
EGR C oolant Return Kits
(Conversion from EGR Cooler
Return Tube to Hose)
Removal of E GR Coolant Return
NOTE: See Technical Service Information (TSI)
bulletin (TSI-07-12-12 EGR Coolant Return Kit, page
477) for Exhaust Gas Recirculation (EGR) kits.
1. Drain coolant to a level below the cylinder head.
2. Remove and save bolt from EGR cooler return
tube flange.
3. Remove spring clip or set screws from EGR return
tube elbow.
4. Remove old EGR return tube and elbow.
Installation of EGR Coolant Return Kit
CAUTION: To prevent engine damage, do not use
engine oil or other petroleum products on EGR coolant
return hose or O-rings.
Figure 132 EGR coolant return elbow
1. EGR coolant return elbow
2. O-ring seal
1. Put O-ring seal on new EGR coolant return elbow.
2. Put O-ring seal on new EGR coolant return
adapter tube.
3. Lubricate both O-rings with P-80 or equivalent.
Figure 133 EGR coolant return
1. EGR coolant return hose
2. Constant tension EGR hose clamp
3. M8 x 25 bolt
4. EGR cooler return adapter tube
5. EGR elbow retaining clip
6. EGR coolant return elbow
4. Install EGR coolant return elbow.
5. Slide new EGR coolant return hose onto c
oolant
return elbow and position hose clamp.
6. Put hose clamp on EGR coolant return hos
e,
insert EGR cooler return adapter tube
into hose,
and position clamp.
7. Install M8 x 25 bolt (finger tight) to
secure EGR
cooler return adapter tube to cyli
nder head.
8. Install EGR elbow retaining clip (
outboard hole
first). Tap top of elbow with rubber
mallet to
ensure retaining clip is fully en
gaged.
9. Tighten M8 x 25 bolt to the standar
d torque
(General Torque Guidelines, p
age445).
10. Tighten constant tension EGR h
ose clamps to the
special torque (Table 10).
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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