NUMBER: 7 4 09 S.M. REF.: Listed in Table 1 ENGINE: DD13 DATE: July 2009 SUBJECT: EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Page Number(s) DDC-SVC-MAN-0050 DD13 Workshop Manual 5.1 Exhaust Gas Recirculation Cooler Water Manifold Assembly The removal and installation procedures of EGR Cooler Water Manifold Assembly have been modified. NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle. Table 1 5 3
EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY The primary purpose of the EGR cooler is to cool the engine exhaust gases prior to entering the intake manifold. Exhaust gas cooling is accomplished by the flow of exhaust gases through the EGR cooler tubes. The EGR cooler core then transfers the heat removed from the exhaust gases to the engine coolant. The cooled exhaust gases are then mixed with incoming air from the Charge Air Cooler (CAC) before being sent to the intake manifold. 1. Clamp 14. Outlet Nipple 2. Hose 15. Seal 3. Coolant Crossover Tube 16. Exhaust Gas Recirculation Cooler Water Manifold Assembly 4. Bolt 17. Clamps 5. Support Plate 18. Exhaust Pipe 6. Coolant Connector Tube 19. Exhaust Gas Crossover Tube / Lifting Eye 7. Exhaust Gas Connector Tube 20. Gasket 8. Gasket 21. Bolt (qty 6) 9. Seal Ring 22. Venturi 10. Banjo Union 23. Mixer Pipe 11. Banjo Bolt 24. O-ring Seal 12. Bolt 25. Bolt 13. Bolt 26. Bolt Figure 1 EGR Cooler Water ManifoldandRelatedParts
REMOVAL OF THE EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY Remove the EGR cooler water manifold assembly as follows: PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Steam clean the engine. 3. Drain the engine coolant. 4. Remove the heat shield from the center exhaust manifold. NOTE: Note the orientation of clamps before removal. 5. Remove the two clamps from the exhaust pipe. 6. Remove the exhaust pipe from EGR cooler water manifold assembly and EGR valve located in the exhaust manifold center housing. 7. Remove heat shield from rear exhaust manifold. 8. Remove inlet coolant line from EGR cooler water manifold assembly to the EGR valve actuator. 9. Remove feed and return coolant lines from EGR cooler water manifold assembly to doser block. 10. Disconnect delta-p sensor. 11. Disconnect coolant outlet temperature sensor at the EGR cooler. 12. Remove two clamps from hose connecting the venturi pipe to the mixer pipe. 13. Remove two bolts from support plate connecting coolant crossover tube and EGR cooler water manifold assembly. 14. Remove one bolt from the exhaust gas crossover tube/lifting eye to coolant crossover tube and one bolt from the coolant crossover tube to exhaust gas crossover tube/lifting eye. 15. Remove two clamps and slide hose from the coolant crossover tube onto coolant module. 16. Remove coolant crossover tube. 17. Remove six bolts holding the exhaust gas crossover tube/lifting eye to the cylinder head and remove exhaust gas crossover tube/lifting eye and the venturi as an assembly. 18. Remove radiator strut and mount from the right side of the engine block. 19. Remove seventeen bolts that attach the EGR cooler water manifold assembly to the cylinder head. Remove the EGR cooler water manifold assembly. 20. Remove and discard gaskets.
INSPECTION OF THE EGR COOLER WATER MANIFOLD ASSEMBLY Inspection as follows: 1. Inspect the EGR cooler water manifold assembly for damage; replace if necessary. 2. Inspect the EGR cooler water manifold assembly connecting tubes; replace if necessary. 3. Perform an EGR Cooler Leak Test. INSTALLATION OF THE EGR COOLER WATER MANIFOLD ASSEMBLY Install the EGR cooler as follows: 1. Install new EGR cooler water manifold assembly gaskets. 2. Install EGR cooler water manifold assembly to the cylinder head. 3. Install and hand tighten seventeen bolts into the EGR cooler water manifold assembly. 4. Torque the bolts to 30 N m (22 lb ft) in the sequence shown. 5. Install the right side radiator mount to the engine block, torque to 60 N m (44 lb ft). See OEM for torque spec on strut to mount. 6. Inspect the coolant connecting tube and EGR connecting tube for cuts, tears, cracks, or for signs of leakage. If damage is found, replace the connecting tube. NOTICE: Ensure items 6 and 7 connecting tubes (refer to Figure "EGR Cooler Water Manifold and Related Parts") are lubricated with clean oil. If the tubes are not lubricated, the tubes cannot not be fully installed, or the rubber can be cut. 7. Install coolant connecting tube and exhaust gas connecting tube to EGR cooler water manifold assembly.
8. Install exhaust gas crossover tube/lifting eye and venturi to mixer pipe. [a] Torque bolts holding exhaust gas crossover tube/lifting eye to cylinder head to 60 N m (44 lb ft). [b] Tighten clamps to 2.5 N m (2 lb ft). 9. Install coolant crossover tube to EGR cooler water manifold assembly and coolant module. [a] Torque two bolts from support plate connecting coolant crossover tube and EGR cooler water manifold assembly to 30 N m (22 lb ft). [b] Install the two clamps at the coolant module; torque to 2.5 N m (2 lb ft). [c] Install one bolt into the coolant crossover tube to EGR crossover tube/lifting eye. Torque to 60 N m (44 lb ft). [d] Install one bolt into the EGR crossover tube/lifting eye to coolant crossover tube. Torque to 60 N m (44 lb ft). 10. Connect outlet temperature sensor at EGR cooler water manifold assembly. 11. Connect delta-p sensor. 12. Install inlet coolant line to the EGR cooler water manifold assembly and EGR valve actuator, torque to 35 N m (25 lb ft). 13. Install feed and return coolant lines from EGR cooler water manifold assembly to doser block, torque to 15 N m (11 lb ft). 14. Install exhaust pipe to EGR cooler water manifold assembly and to exhaust manifold. Tighten clamp bolts to 12 N m (9 lb ft). 15. After installing exhaust pipe, sweep the EGR valve actuator by hand to verify it does not make contact with the clamps. If contact is made, rotate the clamps as needed to gain clearance. 16. Install rear exhaust manifold heat shield. Torque to 20 N m (14 lb ft). 17. Install heat shield on center exhaust manifold and turbocharger. Torque to 20 N m (14 lb ft). 18. If removed, install coolant outlet nipple to EGR cooler water manifold using new seal. Torque to 30 N m (22 lb ft). 19. Connect any removed OEM coolant connections. 20. Fill engine with coolant.
ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. Detroit Diesel, DDC, Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Copyright 2009 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.