Cummins ISX11.9 CM2250 – Service Manual 011-066   EGR Mass Measurement Flow Assembly

WARNING  Wear safety glasses or a face shield, as well as protective clothing, to reduce the possibility of personal injury when using a steam cleaner or high-pressure water.

WARNING  The EGR mass measurement flow assembly tube can be hot. To reduce the possibility of personal injury, allow the engine to cool before removing.

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

• Use steam or high-pressure water to clean the engine, specifically around the EGR mass measurement flow assembly.
• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• If necessary, remove any OEM air cleaner and charge-air plumbing to remove the turbocharger.  Refer to the OEM service manual.
• Remove the EGR differential pressure sensor. Refer to Procedure 019-370 in Section 19.
• Remove the EGR orifice pressure sensor. Refer to Procedure 019-461 in Section 19.
• Remove the EGR temperature sensor. Refer to Procedure 019-378 in Section 19.
• Remove the EGR crossover tube.  Refer to Procedure 011-070 in Section 11.
• Remove the aftertreatment injector coolant return line from the EGR mass measurement flow assembly. Refer to Procedure 011-051 in Section 11.

Remove the EGR mass measurement flow assembly outlet coolant line.

WARNING  The EGR mass measurement flow assembly tube can be hot. To reduce the possibility of personal injury, allow the engine to cool before removing.

Loosen the V-band clamp that connects the EGR mass measurement flow assembly to the EGR valve and slide the V-band over the inlet side of the EGR mass measurement flow assembly.

Loosen the two mounting capscrews.

Remove the EGR mass measurement flow assembly.

Remove the V-band clamp.

Remove and discard the o-rings from the inlet and outlet sides of the EGR mass measurement flow assembly.

Use protective caps from the Air Handling Clean Care Kit, Part Number 4919799, to cover open points on the air handling system.

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 mass measurement flow assembly with safety solvent.

Dry with compressed air.

Inspect the engine wiring harness, EGR differential pressure sensor, and EGR orifice pressure sensor connectors for corrosion, worn receptacles, or other damage.

Replace the engine wiring harness, EGR differential pressure sensor, or EGR orifice pressure sensor connectors if corrosion, worn receptacles, or other damage is found.

Inspect the EGR mass measurement flow assembly for soot plugging at the EGR differential pressure sensing ports and orifice pressure sensor mounting port.

Insert a flexible pipe cleaner or wire through the ports to verify the ports are not plugged inside. Make sure that the pipe cleaner or wire goes past the bend.

If the ports are plugged, the EGR mass measurement flow assembly must be cleaned.

Remove the three straight thread o-ring plugs from the EGR mass measurement flow assembly to gain access to the ports.

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 mass measurement flow assembly ports with safety solvent.

Dry with compressed air.

If cleaning does not open the EGR mass measurement flow assembly ports, the EGR mass measurement flow assembly must be replaced.

If the ports were able to be cleared, apply high temperature anti-seize compound to the three straight thread o-ring plugs.

Install and tighten the plugs.

Inspect the ends and mating joints of the EGR mass measurement flow assembly for signs of fretting, material transfer, cracks, or other damage.

Replace the flow assembly if fretting, material transfer, cracks, or other damage is found.

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

Inspect the EGR mass measurement flow assembly outlet coolant line banjo fittings for damage. Replace if necessary.

Make sure the EGR mass measurement flow assembly outlet coolant line is clear of debris.

Use compressed air to flush the line and remove any loose dirt particles.

Inspect the face of the banjo connection for sealing surface damage.

Replace as necessary.

Install new banjo sealing washers.

Remove the protective caps used from the Air Handling Clean Care Kit, Part Number 4919799, to cover open points on the air handling system.

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 mass measurement flow assembly, coat the clamping surface of the V-bands with high temperature anti-seize compound.

If the V-band clamp was removed, loosely install the V-band clamp over the inlet side of the EGR mass measurement flow assembly.

Install the EGR mass measurement flow assembly to the EGR valve by sliding the V-band in place.

Loosely install the two EGR mass measurement flow assembly mounting capscrews.

Tighten the V-band clamp.

Tighten the two mounting capscrews.

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

• Install the EGR crossover tube.  Refer to Procedure 011-070 in Section 11.
• Install the EGR orifice pressure sensor. Refer to Procedure 019-461 in Section 19.
• Install the EGR differential pressure sensor. Refer to Procedure 019-370 in Section 19.
• Install the EGR temperature sensor. Refer to Procedure 019-378 in Section 19.
• Install the aftertreatment injector coolant return line to the EGR mass measurement flow assembly. Refer to Procedure 011-051 in Section 11.
• If removed, install any OEM air cleaner and charge-air plumbing.  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.