Home » ISX11.9 CM2250 - Service Manual » Cummins ISX11.9 CM2250 – Service Manual 011-070   EGR Crossover Tube

Cummins ISX11.9 CM2250 – Service Manual 011-070   EGR Crossover Tube

Preparatory Steps

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 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 crossover tube can be hot. To reduce the possibility of personal injury, allow the engine to cool before removing.

NOTE: When removing the EGR crossover tube, do not bend the tube at the hose section of the tube. Bending the tube at this location can cause exhaust leaks when the tube is installed.

  • Use steam or high-pressure water to clean the engine, specifically around the EGR crossover tube joints.
  • Some applications may require removal of the air cleaner.  Refer to the OEM service manual. Use protective caps from the Air Handling Clean Care Kit, Part Number 4919425, to cover the connection points.

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Remove

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Remove the p-clip retaining the crossover tube.

NOTE: When removing the EGR crossover tube and the capscrews, be sure not to damage the exhaust gas pressure sensor.

Remove the two mounting capscrews from the EGR crossover tube ends.

Remove the EGR crossover tube.

Remove and discard the press-in-place seals from each end of the crossover tube.

Use protective caps from the Air Handling Clean Care Kit, Part Number 4919425, to cover the connection points.

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Clean and Inspect for Reuse

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 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 crossover tube with safety solvent.

Dry with compressed air.

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Inspect the ends and mating joints of the tube for signs of fretting, material transfer, cracks, or other damage

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

Inspect the EGR crossover tube hose for cracks, fraying, or tearing.

Replace the EGR crossover tube if the hose section is damaged.

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Inspect the p-clip for missing or torn rubber sleeves.

Replace the p-clip if the rubber sleeve is missing or torn.

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Install

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Remove the protective caps used from the Air Handling Clean Care Kit, Part Number 4919425, from the connection points.

Install new press-in-place seals on both mounting surfaces of the crossover tube.

NOTE: When installing the EGR crossover tube and the capscrews, make sure not to damage the exhaust gas pressure sensor.

Install the mounting capscrews on both sides of the EGR crossover tube.

NOTE: Some chassis are equipped with an additional crossover tube p-clip on the exhaust side of the engine.

Tighten the capscrews.

Torque Value:  20  n.m  [177 in-lb]

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NOTE: When installing the EGR crossover tube, the EGR crossover tube brace is used to take up any misalignment or tolerance in the system.

Loosen the capscrews of the EGR crossover tube brace going into the rocker housing.

Install the p-clip around the crossover tube. Install the p-clip capscrew into the EGR crossover tube brace.

Tighten the capscrew of the p-clip.

Torque Value:  20  n.m  [177 in-lb]

Check the EGR crossover tube brace capscrews going into the rocker housing.

Torque Value:  20  n.m  [177 in-lb]

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Finishing Steps

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  • Remove the protective caps used from the Air Handling Clean Care Kit, Part Number 4919425, from the connection points.
  • Install the air cleaner, if removed. Refer to the OEM service manual.
  • Operate the engine and check for leaks.

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Last Modified:  02-Jul-2010