Cummins ISX11.9 CM2250 – Service Manual 011-019   EGR Cooler

NOTE: This test is performed with the EGR cooler mounted on the engine.

Install the plate with the o-ring supplied in the EGR cooler leak check kit, Part Number 4918655, and the supplemental kit, Part Number 4919726, into the coolant inlet side of the EGR cooler. Use two M8 capscrews.

Install a straight threaded plug from the EGR cooler leak check kit, Part Number 4918655, and the supplemental kit, Part Number 4919726, into the vent port.

Install the plate onto the coolant outlet provided in the EGR cooler leak check kit, Part Number 4918655, and the supplemental kit, Part Number 4919726. Use two M8 capscrews.

NOTE: This step is necessary to prevent debris or moisture from entering the EGR piping or EGR valve.

Loosen the V-band clamp at the rear EGR connection tube and place the V-band clamp over the rear EGR connection tube.

Remove and discard the gasket.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

NOTE: Air pressure regulator kit, Part Number 3164231 or equivalent, is suitable for use during this step.

Install the air pressure regulator and hose assembly onto the test fitting on the coolant inlet of the EGR cooler.

Install a ball type shutoff valve onto the inlet side of the air pressure regulator to allow the air supply to be shut off during testing.

Make sure the air pressure regulator and ball type valve are closed.

Connect a compressed air supply to the pressure regulator.

Apply 620 kPa [90 psi] of air pressure to the EGR cooler.

Inspect for air escaping the EGR cooler assembly. Check for loose fittings by spraying the exterior of the EGR cooler and all lines and fittings with a mixture of mild soap and water.

Shut off the air supply to the regulator with the ball valve.

Disconnect the compressed air supply.

Record the time at which the air supply was shut off and the air pressure shown on the air pressure regulator gauge.

Measure and record the air pressure after 15 minutes.

If the measured pressure loss in the EGR cooler is more than 35 kPa [5 psi] in 15 minutes, the EGR cooler must be replaced.

NOTE: If the EGR cooler is determined to not be reusable, be sure the test equipment is functioning propery. Carefully inspect the air pressure regulator, air lines, ball-valve, o-rings, and other components for leaks.  A mixture of mild soap and water can be sprayed onto the assembly to aid in leak detection.

If the EGR cooler is not reusable, inspect the turbocharger turbine housing and rear EGR connection tube for any signs of coolant deposits.

Coolant deposits can be identified as dried white deposits coating the inside of the turbine housing.

If coolant deposits are found, inspect the turbocharger for progressive damage. Coolant can cause the turbocharger to stick. Use the following procedure for inspection guidelines. Refer to Procedure 010-033 in Section 10.

If coolant deposits are found, inspect the EGR valve for progressive damage. Coolant can cause the EGR valve to stick and allow coolant to collect. Remove the EGR valve and inspect for reuse. Refer to Procedure 011-022 in Section 11.

If coolant deposits are found in the EGR valve, inspect the EGR mass measurement flow assembly. Coolant deposits can plug the internal ports of the EGR mass measurement flow assembly. Remove the EGR mass measurement flow assembly and inspect for reuse. Refer to Procedure 011-066 in Section 11.

If the EGR cooler is not reusable, replace the crankcase breather element. Refer to Procedure 003-019 in Section 3.

If the EGR cooler is not reusable, clean the aftertreatment fuel injector. Refer to Procedure 011-054 in Section 11.

NOTE: If the EGR cooler is being replaced due to a malfunction that caused an internal coolant leak, the crankcase breather element must be replaced.

NOTE: If a malfunction resulted in coolant entering the exhaust system, the aftertreatment system can be recovered. Refer to Procedure 014-013 in Section 14.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

NOTE: Use protective caps from the Air Handling Clean Care Kit, Part Number 4919799, to cover all open connection points.

• Drain the engine coolant. Refer to Procedure 008-018 in Section 8.
• Remove the turbocharger. Refer to Procedure 010-033 in Section 10.
• Remove the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Remove the EGR cooler conection. Refer to Procedure 011-024 in Section 11.
• Remove the rear EGR connection tube. Refer to Procedure 011-069 in Section 11.

Use protective caps from the Air Handling Clean Care Kit, Part Number 4919799, to cover the open points on both the EGR cooler and the EGR plumbing.

CAUTION  The EGR cooler is not to be removed from the EGR mounting brackets. Adjusting or removing the EGR cooler from the EGR mounting brackets can damage the EGR cooler.

Remove the eight capscrews that attach the EGR valve mounting bracket.

Remove the EGR cooler assembly from the engine.

Use protective caps from the Air Handling Clean Care Kit, Part Number 4919799, to cover the open ports on the EGR cooler and exhaust manifold.

Inspect the V-band clamps and EGR bellows. Refer to Procedure 011-024 in Section 11.

Inspect the EGR cooler for cracks or other damage.

Replace the EGR cooler if cracks or other damage is found.

WARNING  Do not use chlorinated water to clean or rinse the EGR cooler. Chlorides are very corrosive to the stainless alloys internal and external to the EGR cooler.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

Cap the outlet end of the EGR cooler with the plastic caps supplied in the EGR cooler leak check kit, Part Number 4918655, and the supplemental kit, Part Number 4919726.

Completely fill the EGR cooler with safety solvent.

Cap the gas inlet end of the EGR cooler with the plastic cap supplied in the EGR cooler leak check kit, Part Number 4918655, and the supplemental kit, Part Number 4919726.

Lay the EGR cooler on its side.

Allow the EGR cooler to soak for approximately 20 minutes.

Drain approximately 25 percent of the liquid from the cooler and recap. Dispose of the liquid properly.

Shake the cooler by hand, from end to end, for approximately 30 seconds.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Drain the safety solvent from the EGR cooler and properly dispose of the liquid.

Use compressed air to dry the inside of the EGR cooler and remove any loose debris or particles.

Cap the outlet end of the EGR cooler with the plastic cap supplied in the EGR cooler leak check kit, Part Number 4918655, and the supplemental kit, Part Number 4919726.

Completely fill the EGR cooler with water.

Cap the gas inlet end of the EGR cooler with the plastic cap supplied in the EGR cooler leak check kit, Part Number 4918655, and the supplemental kit, Part Number 4919726.

Shake the cooler by hand, from end to end, for approximately 30 seconds.

Drain the water from the EGR cooler and properly dispose of the liquid.

Use compressed air to dry the inside of the EGR cooler.

Replace the EGR cooler if cracks or other damage is found.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Clean the EGR cooler exhaust gas outlet with safety solvent.

Dry with compressed air.

Inspect the EGR cooler exhaust gas outlet for signs of fretting, cracks, or other damage.

Replace the EGR cooler if any damage is found.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

Clean the mounting surfaces with safety solvent to remove any coolant deposits or debris.

Clean the EGR cooler coolant inlet and outlet surfaces, to remove any coolant deposits or debris. Otherwise, the press-in-place seal joint can leak.

Clean the EGR cooler coolant supply and return tubes to remove any coolant deposits or debris at the o-ring joint.

Remove the protective caps from the Air Handling Clean Care Kit, Part Number 4919799, used to cover the open ports on the EGR cooler and exhaust manifold.

Apply a film of high-temperature anti-seize compound to the inside of the V-band clamp to make sure of proper loading on the clamp.

Install a V-band clamp onto the EGR cooler bellows.

Install a new gasket on the pilot end of the EGR cooler, where it connects to the EGR cooler bellows.

Install the EGR cooler on the studs in the lubricating oil cooler assembly.

Install the eight EGR cooler mounting capscrews.

Tighten the capscrews and nuts in the sequence shown.

CAUTION  Do not use air tools to remove or install the nut on the v-band clamp. Use of these tools can seriously damage the threads or the bolt and cause the clamp to not be able to be reused.

Position the V-band clamp onto the EGR cooler inlet connection.

Tighten the clamp.

Install a new gasket on the pilot end of the EGR gas outlet where it connects to the rear EGR connection tube.

Position the V-band clamp at the rear EGR connection tube and EGR cooler gas outlet.

Tighten the clamp.

• Install the EGR cooler coolant lines. Refer to Procedure 011-031 in Section 11.
• Install the EGR cooler connection. Refer to Procedure 011-024 in Section 11.
• Install the rear EGR connection tube. Refer to Procedure 011-069 in Section 11.
• Install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Fill the engine cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine to check for leaks and verify that all fault codes are inactive.

NOTE: If a malfunction resulted in coolant, oil, excessive fuel, or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013 in Section 14.