Cummins ISX11.9 CM2250 – Service Manual 011-022   EGR Valve

NOTE: Brush away all loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

NOTE: Some chassis may require the removal of the EGR mass measurement flow assembly and exhaust transfer elbow connection to better gain access the EGR valve.

• If required, remove the EGR mass measurement flow assembly. Refer to Procedure 011-066 in Section 11.
• Disconnect the wiring harness from the EGR valve mounting bracket attachment points around the EGR valve.
• Remove the rear EGR connection tube. Refer to Procedure 011-069 in Section 11.

Disconnect the EGR valve electrical connector.

Disconnect the wire harness from the EGR valve mounting location.

Loosen the hose clamp on the EGR valve.

NOTE: For ease of removal, run a hose pick under the EGR system hose on the inlet side of the EGR valve.

Remove and discard the EGR system hose from the rear EGR connection tube. Refer to Procedure 011-034 in Section 11.

If the mass measurement flow assembly has not been removed, loosen the V-band clamp between the EGR valve and the mass measurement flow assembly.

Slide the V-band over the intake side of the mass measurement flow assembly.

Make sure to support the EGR valve by hand before removing the mounting capscrews. If the EGR valve is not supported, it can fall off of the engine, causing damage to the EGR valve.

Loosen and remove the three EGR valve mounting capscrews.

Remove the EGR valve from the EGR valve support bracket.

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

If required, disassemble the EGR valve from the EGR valve brace by removing the three EGR valve mounting capscrews.

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 EGR valve mounting and sealing surfaces with safety solvent to remove any deposits or debris.

Inspect the EGR butterfly valve for a stuck open condition. If the EGR valve is stuck open, replace the EGR valve. Do not try to pry the butterfly valve open or closed.

Inspect the inside of the valve for cracks, broken butterfly valve, or other damage.

Replace the EGR valve if any damage is found.

Inspect the EGR valve actuator for cracks or other damage. Replace the valve actuator if any damage is found.

Inspect the EGR valve actuator connector for corrosion, worn pins, or other damage.

Replace the EGR valve assembly if corrosion, worn pins, or other damage is found.

Inspect the engine wiring harness EGR valve actuator connector for corrosion, worn receptacles, or other damage.

Replace the engine wiring harness EGR valve connector if corrosion, worn receptacles, or other damage is found.

Soot leakage at the EGR valve weep hole is normal and is to be expected. Do not replace the EGR valve if soot streaks are found at the EGR valve weep hole.

If disassembled, assemble the EGR valve to the EGR valve brace by installing the three EGR valve mounting capscrews.

Tighten the EGR valve mounting capscrews.

Remove the protective caps from the Air Handling Clean Care Kit, Part Number 4919799, used to cover open points on the EGR valve and plumbing.

Push the o-ring over the flow assembly pilot by hand.

The o-ring must remain square during installation. Do not allow the o-ring to roll or twist.

Before installing the EGR valve, coat the clamping surface of the V-band with high temperature anti-seize compound.

Slide the V-band over the intake side of the mass measurement flow assembly, if it was not removed from the engine.

Align the EGR valve brace mounting holes with their corresponding holes in the EGR valve mounting bracket.

Tighten the three EGR valve mounting capscrews by hand to hold the EGR valve in place.

Slide the V-band in place over the EGR valve outlet and EGR mass measurement flow assembly inlet.

Tighten the V-band clamp.

Hand-tighten the three EGR valve brace capscrews into the EGR valve mounting bracket.

Tighten the capscrews.

Install a new EGR system hose. Refer to Procedure 011-034 in Section 11.

Apply lubricant to the hose end of the EGR valve. Slide the hose clamp over the EGR hose.

Slide the EGR valve into the EGR system hose. Make sure that the hose slides past the hose bead on the EGR valve.

Connect the EGR valve electrical connector.

• Install the rear EGR connection tube. Refer to Procedure 011-069 in Section 11.
• Connect the wiring harness to the EGR valve mounting bracket attachment points around the EGR valve.
• If removed, install the EGR mass measurement flow assembly. Refer to Procedure 011-066 in Section 11.
• Operate the engine and check for leaks and proper operation.