Cummins ISX11.9 CM2250 – Service Manual 011-024   EGR Cooler Connection

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

• If needed, remove any OEM air cleaner and charge-air cooler plumbing to obtain access to the EGR cooler bellows connection. Refer to the OEM service manual.
• If needed, remove the air inlet connection to obtain access to the EGR cooler bellows. Refer to Procedure 010-022 in Section 10.
• Remove the heat shield. Refer to Procedure 011-032 in Section 11.

NOTE: The EGR cooler inlet bellows can be easily damaged. Use care when loosening the V-band clamp between the EGR cooler and the inlet bellows.

Loosen the V-band clamps on each end of the EGR cooler connection.

Remove the EGR cooler connection and V-bands.

Remove and discard the gaskets.

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

Remove any OEM air cleaner and charge-air cooler plumbing needed to remove the turbocharger. Refer to the OEM service manual.

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 connection with safety solvent.

Dry with compressed air.

Inspect the EGR cooler connection for cracks or other damage.

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

Clean the EGR cooler mounting flange with safety solvent.

Dry with compressed air.

Inspect the EGR cooler mounting flange for cracks or other damage. Replace the EGR cooler, if cracks or other damage is found. Refer to Procedure 011-019 in Section 11.

Inspect the V-band clamps for signs of over extension. The band must not be bent or cracked.

Inspect the V-band clamp threads for damage.

Replace the V-band clamp if damage is found.

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

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

The EGR cooler connection has a male and female end. The male end of the connection goes to the exhaust manifold; the female end goes to the EGR cooler.

Install new gaskets on the pilot end of the EGR cooler connection and the EGR valve.

Install the V-band clamps loosely on the EGR cooler connection.

Install the EGR cooler bellows.

Position the V-band clamps that hold the EGR cooler bellows between the EGR cooler and the exhaust manifold, as illustrated.

Rotate the exhaust manifold V-band clamp into position, as illustrated, and tighten the V-band clamps.

• Install the heat shield. Refer to Procedure 011-032 in Section 11.
• If removed, install any OEM air cleaner and charge-air cooler plumbing removed to obtain access to the EGR cooler bellows connection.  Refer to the OEM service manual.
• If removed, install the air inlet connection. Refer to Procedure 010-022 in Section 10.
• Operate the engine and check for leaks and proper operation.