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112
EGR Coolant Return Kits
(Conversion from EGR Cooler
Return Tube to Hose)
Removal of EGR 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.
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
EGR COOLER AND TUBING
3. Lubricate both O-rings with P-80 or equivalent.
Figure 133 EGR coolant return
1.
2.
3.
4.
5.
6.
4. Install EGR coolant return elbow.
5. Slide new EGR coolant return hose onto coolant
6. Put hose clamp on EGR coolant return hose,
7. Install M8 x 25 bolt (finger tight) to secure EGR
8. Install EGR elbow retaining clip (outboard hole
9. Tighten M8 x 25 bolt to the standard torque
10. Tighten constant tension EGR hose clamps to the
EGES-265-2
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
EGR coolant return hose
Constant tension EGR hose clamp
M8 x 25 bolt
EGR cooler return adapter tube
EGR elbow retaining clip
EGR coolant return elbow
return elbow and position hose clamp.
insert EGR cooler return adapter tube into hose,
and position clamp.
cooler return adapter tube to cylinder head.
Tap top of elbow with rubber mallet to
first).
ensure retaining clip is fully engaged.
(General Torque Guidelines, page445 ).
special torque (Table 10).
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