Cummins ISX11.9 CM2250 – Service Manual 011-031   EGR Cooler Coolant Lines

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.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove any OEM air cleaner and charge-air cooler plumbing needed to remove the coolant lines.  Refer to the OEM service manual. Use protective caps from the Air Handling Clean Care Kit, Part Number 4919799, to cover the connection points.

CAUTION  Be sure all the components are clean and free of debris that can cause damage to o-ring seals.

Disconnect the EGR cooler coolant vent line from the rocker housing and the EGR cooler.

Remove the EGR cooler coolant return tube mounting capscrews at the EGR cooler coolant outlet and at the oil cooler housing.

Discard the press in place seal at the EGR cooler coolant outlet.

Slide the EGR cooler coolant return tube at the oil cooler housing rearward, to disengage the o-ring seal.

Remove the EGR cooler coolant return tube from the engine.

Remove and discard the o-ring.

Remove the EGR cooler coolant supply tube mounting capscrews at both the EGR coolant inlet and the water pump housing.

Discard the press in place seal at the EGR cooler coolant inlet.

Slide the EGR cooler coolant supply tube rearward until the EGR cooler coolant supply tube is disengaged from the water pump outlet.

Remove the EGR cooler coolant supply tube from the engine.

Remove and discard the o-ring.

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 coolant vent line and the EGR cooler coolant supply and return tubes with safety solvent.

Dry with compressed air.

Inspect the EGR cooler lines grommets for damage. Replace the grommets if they are damaged.

CAUTION  Do not use petroleum products on the EGR cooler coolant line o-rings or press-in-place seals. The o-rings and press-in-place will swell and cause the connection to leak.

Install a new o-ring and press-in-place seal on the EGR cooler coolant supply tube.

Lubricate the o-ring with clean engine coolant, soapy water, or vegetable oil, to aid in installation.

Insert the EGR cooler coolant supply tube into the water pump outlet.

Install the EGR cooler coolant supply tube retaining clamp and capscrew.

NOTE: Do not tighten the capscrew at this time.

Attach the EGR cooler coolant supply tube into the EGR cooler coolant inlet.

Install the mounting capscrews to the EGR cooler.

NOTE: Do not tighten the capscrew at this time.

Tighten the capscrews in the following sequence.

Tighten the EGR cooler coolant supply tube mounting capscrews (1).

Tighten the EGR cooler coolant supply tube retaining clamp capscrew (2) to the water pump.

Install the EGR cooler coolant vent line to the rocker housing and the EGR cooler.

CAUTION  Do not use petroleum products on the EGR cooler coolant line o-rings or press in place seals. The o-rings and press in place seals will swell and cause the connection to leak.

Install the press-in-place seal and o-ring on the EGR cooler coolant return tube.

Lubricate the o-ring with clean engine coolant, soapy water, or vegetable oil to aid in installation.

Insert the EGR cooler coolant return tube into the oil cooler housing.

Install the EGR cooler coolant return tube retaining clamp and capscrew.

NOTE: Do not tighten the capscrews at this time.

Attach the EGR cooler coolant return tube into the EGR cooler coolant outlet.

Install the mounting capscrews to the EGR cooler.

NOTE: Do not tighten the capscrew at this time.

Tighten the capscrews in the following sequence.

Tighten the EGR cooler coolant return tube mounting capscrews (1).

Tighten the EGR cooler coolant return tube retaining clamp capscrew (2) to the oil cooler housing.

• Remove the protective caps from the intake piping.
• Install the intake piping. Refer to the OEM service manual.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for leaks.