EGR heater plate removal and installation procedure has been added.

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1 NUMBER: S.M. REF.: 8.3 ENGINE: EPA07 Series 60 DATE:June 2008 SUBJECT: EGR HEATER PLATE PUBLICATION: DDC-SVC-MAN-0005 EGR heater plate removal and installation procedure has been added.

2 8.3.1 REMOVAL OF EGR HEATER PLATE The primary purpose of the EGR heater plate is to prevent ice build up in the EGR mixer housing during cold ambient temperature operation. The EGR heater plate uses engine coolant to heat the exhaust gases and maintains manifold temperature above 0 C (32 F). Engine coolant flows from the air compressor to the heater plate and then back to the water pump. The EGR mixer housing has a diffuser behind the Intake Throttle Valve (ITV) which also helps prevent icing. A calibration change has been made to prevent flow of EGR until the engine coolant temperature is above 75 C (176 F). Removal steps are as follows: PERSONAL INJURY To avoid injury, never remove any engine component while the engine is running. PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component. 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.

3 PERSONAL INJURY To avoid injury from scalding, drain the radiator when the engine and coolant are cool. 1. Shut off the engine and apply the parking brake, chock the wheels, disconnect vehicle battery power, and perform any other applicable safety steps. 2. Drain engine coolant. 3. Loosen the two clamps that secure the EGR delivery pipe hose to the venturi or the EGR valve inlet pipe (depending on engine configuration). 4. Disconnect the Engine Harness from the EGR valve. See Figure EGR Valve 3. Bolt 2. EGR Heater Plate 4. Engine Harness Figure 1 EGR Heater Plate

4 5. Disconnect the coolant supply hose for the EGR heater plate at the air compressor. See Figure Coolant Supply Hose to Air Compressor 2. Coolant Return Hose to Coolant Return Line Connection Figure 2 Coolant Supply and Return Hoses 6. Disconnect coolant return hose from coolant return line. See Figure 2 7. Remove all bolts (see Figure 1), holding either the venturi or the EGR valve inlet pipe (depending on engine configuration), EGR valve and heater plate to mixer housing. 8. Push venturi or EGR valve inlet pipe (depending on engine configuration) up into the EGR delivery pipe hose to gain clearance to remove EGR valve and heater. 9. Remove the EGR valve and heater discarding the seals. See Figure 1.

5 10. If replacing the EGR heater plate, remove both coolant hoses and fittings from the EGR heater plate, noting locations of the coolant hoses. See Figure Pipe Plug 3. Coolant Return Hose 2. EGR Heater Plate 4. Coolant Supply Hose Figure 3 EGR Heater Plate and Hoses

6 8.3.2 INSTALLATION OF EGR HEATER PLATE Installation steps are as follows: 1. Install coolant hose fittings that were removed from original EGR heater plate. Torque fitting to 47 N m (35 lb ft). See Figure Install coolant feed and return hose on correct fitting location. Coolant return hose needs to be the farthest from the pipe plug. Torque coolant lines to 55 N m (41 lb ft). See Figure Install EGR heater plate, EGR valve and venturi or EGR valve inlet pipe (depending on engine configuration) onto mixer housing with new seals. Torque all bolts in a cross pattern to N m (22-28 lb ft). See Figure Connect coolant supply hose for EGR heater plate to air compressor. Torque fitting to 55 N m (41 lb ft). See Figure Connect coolant return hose. Torque to 55 N m (41 lb ft). 6. Torque both clamps for EGR delivery pipe hose to 5 N m (45 lb in). Verify that venturi or EGR valve inlet pipe (depending on engine configuration) and delivery pipe are not touching each other. 7. Fill cooling system. To avoid injury or injury to bystanders, engine or vehicle fuel system service operations should be performed in a well-ventilated area. PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. 8. Start engine and check for leaks. 9. Shut down engine when completed.

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8 ADDITIONAL SERVICE INFORMATION Additional service information is available in the Detroit Diesel Series 60 Service Manual, DDC-SVC-MAN The next revision to this manual will include the revised information. Detroit Diesel, DDC, Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Copyright 2008 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.