EGR

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Section 16.1
Tube and Shell Bolted Flange EGR Cooler

The primary purpose of the Tube and Shell Bolted Flange (TSBF) EGR cooler is to cool
the engine exhaust gases prior to entering the intake manifold. Exhaust gas cooling is
accomplished by the flow of exhaust gases through the TSBF EGR cooler tubes. The TSBF
EGR cooler core then transfers the heat removed from the exhaust gases to the engine
coolant. The cooled exhaust gases are then mixed with incoming air from the charge air
cooler before being sent to the intake manifold.

Section 16.1.1
Removal of Tube and Shell Bolted Flange EGR Cooler

Removal steps are as follows:

Note: The following removal procedures support engines built after April 15, 2004 or
engines that have had right-side kits installed.

PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.

1. Drain the engine coolant.Refer to "13.6.4 Cooling System" .

2. Remove two bolts and seal ring from water pump outlet elbow. Discard seal ring.
3. Remove water pump outlet elbow from the hose on cooler water inlet.
4. Remove hose and clamps from cooler water inlet.
5. Loosen and slide the clamp onto hose of oil cooler water inlet.
6. Loosen the two clamps securing the bellow to the EGR valve assembly and upper
hot pipe. See Figure "Tube and Shell Bolted Flange EGR Cooler and Related Parts"
.
 7 .Exhaust Manifold End
1. TSBF EGR Cooler
Section
2. EGR Hydraulic and Pneumatic Actuator 8. Exhaust Manifold Center
Assembly Section
9. Exhaust Manifold Ens
3. Clamp
Section
4. Upper Hot Pipe 10. Bellow
5. Gasket 11. EGR Valve Assembly
6. Stud 12. Gasket

Figure 1. Tube and Shell Bolted Flange EGR Cooler and Related Parts

NOTICE:
The bellow is a one-time usage component, discard after removal.

7. Remove the bellow and the clamps from the upper hot pipe and the EGR valve
assembly. Discard the bellow. See Figure "Tube and Shell Bolted Flange EGR
Cooler and Related Parts" .
 1. Exhaust Manifold Center 4. Upper Hot
7. Bellow
Section Pipe
2. Stud 5. Nut 8. EGR Valve
Assembly
3. Gasket 6. Clamp 9. TSBF EGR Cooler

Figure 2. Tube and Shell Bolted Flange EGR Cooler and Related Parts

Note: Perform step 8 for hydraulically actuated EGR valves and step 9 for
pneumatic actuated EGR valves.

8. Remove the oil inlet fitting and the oil outlet fitting from the EGR valve and
hydraulic actuator. See Figure "Hydraulic EGR Valve Oil Inlet Line and Oil Outlet
Line" .
 1. EGR Valve and Hydraulic Actuator 3. Oil Inlet Line and
Assembly Fitting
2. Oil Outlet Line and Fitting

Figure 3. Hydraulic EGR Valve Oil Inlet Line and Oil Outlet Line

9. Remove the air line from the pneumatic actuator assembly. See Figure "EGR Valve
and Pneumatic Actuator Assembly" .

1. EGR Valve and Pneumatic Actuator Assembly 2. Air line

Figure 4. EGR Valve and Pneumatic Actuator Assembly

10. Remove the three nuts from the studs securing the EGR valve and actuator
assembly to the cooler. Remove the EGR assembly and gasket. Discard the gasket.
See Figure "EGR Valve Assembly and Related Parts" .

1. Nut 4. Stud
2. EGR Valve and Actuator Assembly 5. TSBF EGR Cooler
3. Gasket

Figure 5. EGR Valve Assembly and Related Parts

11. Remove the Delta P tubes. See Figure "Tube and Shell Bolted Flange EGR Cooler
and Delivery Pipe" .
12. Remove the delivery pipe clamp from the cooler outlet and then remove the
delivery pipe. See Figure "Tube and Shell Bolted Flange EGR Cooler and Delivery
Pipe" .
 1. Clamp 3. EGR Cooler
2. Venturi-Section 4. Air Lines

Figure 6. Tube and Shell Bolted Flange EGR Cooler and Delivery Pipe

PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the
component is properly supported and securely attached to an adequate lifting device
to prevent the component from falling.

13. While supporting the cooler, remove the four bolts attaching the cooler backplate to
the engine block. and remove the cooler.
14. Remove the hose and the clamp from the oil cooler water inlet.

Section 16.1.1.1
Inspection and Testing the Tube and Shell Bolted Flange EGR Cooler

Engines equipped with a TSBF cooler that have a coolant-lost complaint need to be
inspected for leaks from other sources. The spring wire hose clamps are a possible coolant
leak path, and should be inspected. If the spring wire clamps are damaged, service kits are
available to replace the damaged components.
A standard test to pressurize the coolant system and investigation of overall coolant system
should have been performed prior to inspecting the cooler. There may be other components
of the engine that are responsible for the loss of engine coolant.

Note: Coolers with internal leaks usually show signs of a white coolant drop-out at the
exhaust side of the cooler, the Delta P Sensor lines, or at the delivery pipe to intake
manifold connector.

If the entire system has been tested, perform the following steps to inspect the cooler:

1. Use hoses, clamps, plugs, and a regulator to seal the cooler water inlet and water
outlet ports. See Figure "EGR Cooler Ports Setup" .

Figure 7. EGR Cooler Ports Setup

2. Fill the exhaust side of the cooler with hot tap water. Allow the water to overflow
until the loose carbon has floated away allowing for a clear viewing of any bubbles.
See Figure "Filling the EGR Cooler with Tap Water" .
 Figure 8. Filling the EGR Cooler with Tap Water

3. Apply 207 kPa (30 psi) of regulated air to the regulator for three minutes. See
Figure "EGR Cooler Ports Setup" .
4. Disconnect the regulated air supply from the regulator and watch for bubbles on the
exhaust side of the cooler. See Figure "Observing the EGR Cooler for Bubbles" .
1. If bubbles were observed, replace the cooler.
2. If no bubbles were observed, contact the Detroit Diesel Customer Support
Center (800–445–1980) for further information.
 Figure 9. Observing the EGR Cooler for Bubbles

Section 16.1.2
Installation of the Tube and Shell Bolted Flange EGR Cooler

Installation steps are as follows:

1. Install the EGR water outlet hose and clamps onto the oil cooler inlet. See Figure
"EGR Cooler and Related Parts" .
 1. Bolt 3. Clamp
2. EGR Water Inlet Hose 4. TSBF* EGR Cooler

Figure 10. EGR Cooler and Related Parts

* Tube and Shell Bolted Flange

2. Insert the oil cooler inlet hose over the cooler water outlet. Secure the hose with
clamps.

PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the
component is properly supported and securely attached to an adequate lifting device
to prevent the component from falling.

3. Align the cooler back plate holes with the four bosses on the cylinder block.
4. Thread four M10 bolts through the back plate and into the cylinder block. Torque
bolts to 46-52 N·m (34-38 lb·ft).
5. Install the hose and clamps onto the cooler water inlet. See Figure "EGR Cooler and
Related Parts" .
6. Insert the water pump outlet elbow into the EGR cooler water inlet hose. Secure the
hose with clamps.
7. Install a new seal ring on the water pump elbow and secure the elbow with two M10
bolts. Torque bolts to 58-73 N·m (43-54 lb·ft).
8. Secure the delivery pipe clamp to the cooler outlet. Torque the clamp nut to 12 N·m
(106 lb·in.). See Figure "Tube and Shell Bolted Flange EGR Cooler and Delivery
Pipe" .
 1. Clamp 3. EGR Cooler
2. Venturi-Section 4. Air Lines

Figure 11. Tube and Shell Bolted Flange EGR Cooler and Delivery Pipe

9. Attach the Delta P tube fittings to the venturi tube. See Figure "Tube and Shell
Bolted Flange EGR Cooler and Delivery Pipe" .
10. Torque the tube fittings to 24-30 N·m (18-22 lb·ft).
11. If the TSBF EGR cooler studs have not been installed, use the following procedure:
1. Install three M8 studs into the threaded holes on the cooler.
2. Torque the studs to 28-32 N·m (21-24 lb·ft).
12. If the upper hot pipe and gasket have not been installed, use the following
procedure:
1. Install gasket and upper hot pipe onto the exhaust manifold center section
studs.
2. Install two nuts on the studs to secure the upper hot pipe.
3. Torque the nuts to 22-26 N·m (16-19 lb·ft).
13. Loosely install the bellow to the EGR valve assembly and secure using the bellow
clamps.
14. Slip the remaining bellow clamp over the flange of the upper hot pipe.
15. Install a new EGR cooler gasket.
16. Align the bellow with the upper hot pipe and while pressing against the upper hot
pipe, lower the EGR valve assembly onto the TSBF EGR cooler studs.
17. Install the three nuts to secure the EGR valve to the TSBF EGR cooler.
18. Torque the nuts to 22-26 N·m (16-19 lb·ft).

Note: Bellow clamps must be positioned correctly for exhaust manifold mid-setback
and high-mount center sections. See figure "Bellow Clamp Orientation for High-
 Mount or Mid-Setback Center Section Exhaust Manifolds" for correct clamp
orientation.

1. Exhaust Manifold Mid-Setback 7. Bellow

Center Section
2. Stud 8. EGR Valve-to-Bellow Clamp
Orientation for all Engines
3. Gasket 9. Exhaust Manifold High-Mount
Center Section
4. Upper Hot Pipe 10. Clamp Orientation for a High-
Mount Center Section
5. Nut 11. TSBF EGR Cooler
6. Bellow Clamp Orientation Mid-
Setback Center Section

Figure 12. Bellow Clamp Orientation for High-Mount or Mid-Setback Center

Section Exhaust Manifolds

19. Torque nut on bellow clamps to 12 N·m (106 lb·in.).

NOTICE:
 Particle debris in the lubrication inlet and outlet ports of the actuator assembly can
cause performance problems. Use care to keep any debris out of the actuator and oil
lines when servicing.See Figure "EGR Valve and Hydraulic Actuator Oil Inlet and
Outlet Locations" .

20.

1. Oil Inlet 2. Oil Outlet

21. Figure 13. EGR Valve and Hydraulic Actuator Oil Inlet and Outlet Locations
22. Install the oil inlet and outlet fittings to the hydraulic actuator assembly. Torque the
fittings to 24-28 N·m (18-21 lb·ft). See Figure "EGR Valve and Hydraulic Actuator
Assembly" .

1. EGR Valve and Hydraulic Actuator 3. Oil Inlet Line and

Assembly Fitting
 2. Oil Outlet Line and Fitting

Figure 14. EGR Valve and Hydraulic Actuator Assembly

23. Install air line fitting to the pneumatic actuator assembly. Torque to 19-22 N·m (14-
16 lb·ft). See Figure "EGR Valve and Pneumatic Actuator Assembly" .

1. EGR Valve and Pneumatic Actuator Assembly 2. Air line Tube

Figure 15. EGR Valve and Pneumatic Actuator Assembly

Section 16.1.2.1
Checking Pneumatic Actuator Assembly Calibration

Measure pneumatic actuator rod end travel as follows.

1. Install a dial indicator.

2. Adjust the stem of the dial indicator to rest on the rod end of the pneumatic actuator
assembly. See Figure "Pneumatic Actuator Assembly" .
3. With the valve closed and no pressure to the actuator set the dial indicator to zero.

EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye
protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air
 EYE INJURY
pressure.

4. Using shop air, a pressure regulator and pressure gage, increase pressure at the
actuator to 152 kPa (22.0 psi). Rod end travel with 152 kPa (22.0 psi) at the actuator
should measure between 0.69-0.83 mm (0.027-0.033 in.).
5. If calibration is not correct, adjust by loosening the jam nut and rotating the adjuster
COUNTER CLOCKWISE to INCREASE the dial indicator reading or
CLOCKWISE to DECREASE the dial indicator reading.. See Figure "Pneumatic
Actuator Assembly" .

1. EGR Valve Assembly and Pneumatic

4. Jam Nut
Actuator Assembly
5. Pneumatic Actuator
2. Rod End
Assembly
3. Adjuster

Figure 16. Pneumatic Actuator Assembly

Note: Tightening the jam nut will stretch the rod end and change the calibration setting.
After adjustment the rod end should be checked with the jam nut tightened. The torque
specification for the jam nut is 25-28 N·m (18.4-20.7 lb·ft). Repeat step 5 if necessary.

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Section 16.2
Hydraulic EGR Valve

The EGR valve position is controlled by DDEC. The ECU continuously monitors all
engine operation modes and performs self diagnostic checks of RPM, load, altitude, air
temperature, etc. and uses this information to determine the valve position.

When the EGR valve is closed, exhaust gas will flow from the exhaust manifold and
through the turbine wheel in the turbocharger, and out the exhaust system. When the
EGR valve is open, some of the exhaust gas is directed into the EGR cooler, through the
delivery pipe, and into the intake manifold.

Section 16.2.1
Removal of Hydraulic EGR Valve

Removal steps are as follows:

1. Loosen the one clamp (3) securing the bellow (10) to the EGR valve assembly (11).
See Figure "Tube and Shell Bolted Flange EGR Cooler and Related Parts" .

7. Exhaust Manifold End

1. TSBF EGR Cooler
Section
2 .EGR Hydraulic and Pneumatic Actuator 8. Exhaust Manifold Center
Assembly Section
9. Exhaust Manifold End
3 Clamp
Section
4.Upper Hot Pipe 10.Bellow
 5.Gasket 11.EGR Valve Assembly
6.Stud 12.Gasket

Figure 1. Tube and Shell Bolted Flange EGR Cooler and Related Parts

2. Remove the oil inlet fitting (3) and the oil outlet fitting (2) from the EGR valve and
hydraulic actuator assembly (1). See Figure "EGR Valve and Hydraulic Actuator" .

1. EGR Valve and Hydraulic Actuator 3. Oil Inlet Line and

Assembly Fitting
2. Oil Outlet Line and Fitting

Figure 2. EGR Valve and Hydraulic Actuator

3. Remove the three nuts (1) from the studs (4) that secure the EGR valve and actuator
assembly (2) to the cooler (5). See Figure "EGR Valve Assembly and Related Parts"
.
 1. Nut 4. Stud
2. EGR Valve and Actuator Assembly 5. TSBF EGR Cooler
3. Gasket

Figure 3. EGR Valve Assembly and Related Parts

4. Remove the EGR assembly (2) and gasket (3). Discard the gasket. See Figure "EGR
Valve Assembly and Related Parts" .

Section 16.2.2
Removal and Installation of EGR Valve Hydraulic Fittings

Remove and install as follows:

1. Remove hydraulic lines from EGR valve fittings.

2. Remove fittings from EGR valve (1).
 Figure 4. EGR Valve Hydraulic Fittings

3. Install two new fittings into EGR valve, Torque fittings to 30-35 N·m.(22-26 lb·ft)
4. Install hydraulic lines and torque to 24-28 N·m.(18-21 lb·ft)

Section 16.2.3
Disassembly of Hydraulic EGR Valve Assembly

Disassembly steps are as follows:

NOTICE:
The actuator assembly can be separated from the EGR valve assembly.DO NOT
disassemble the actuator or EGR valve assemblies.

1. Remove the bolts (6) that secure the hydraulic actuator assembly (5) to the
EGR valve assembly (1). See Figure "EGR Hydraulic Actuator and Related Parts" .
 1. EGR Valve 4. Splined Internal Drive
6. Bolts
Assembly
2. Insulator Shield 5. Hydraulic Actuator 7. Splined External
Assembly Shaft
3. Heat Shield

Figure 5. EGR Hydraulic Actuator and Related Parts

2. Remove the hydraulic actuator assembly (5), heat shield (3), and insulator shield (2)
from the EGR valve assembly (1). See Figure "EGR Hydraulic Actuator and
Related Parts" .

NOTICE:
The insulator cannot be reused and should be replaced whenever the hydraulic
actuator is removed from the EGR valve assembly. Reuse of the insulator shield
will damage the EGR assembly.

3. Discard the insulator shield (2). See Figure "EGR Hydraulic Actuator and Related
Parts" .

Section 16.2.3.1
Cleaning of Hydraulic EGR Valve Spline Drive and Actuator Assembly

Cleaning steps are as follows:

1. Use a wire brush to remove debris and dirt from the splined internal drive (4) and
splined external shaft (7). See Figure "EGR Hydraulic Actuator and Related Parts" .
 EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye
protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air
pressure.

2. Use compressed air to remove dirt and debris from splined internal drive (4) and
splined external shaft (7). See Figure "EGR Hydraulic Actuator and Related Parts" .

Section 16.2.3.2
Inspection of Hydraulic EGR Valve Spline Drive and Actuator Assembly

Inspection steps are as follows:

1. Visually inspect the hydraulic actuator assembly (5) for excessive wear and defects.
See Figure "EGR Hydraulic Actuator and Related Parts" .
1. If the actuator assembly is excessively worn or defective, replace the
actuator assembly.
2. If the actuator assembly is not excessively worn or defective, reuse the
actuator assembly.
2. Visually inspect the EGR valve assembly (1) for excessive wear and defects. See
Figure "EGR Hydraulic Actuator and Related Parts" .
1. If the EGR valve is excessively worn or defective, replace the valve
assembly.
2. If the EGR valve is not excessively worn or defective, reuse the valve
assembly.

Section 16.2.4
Assembly of Hydraulic EGR Valve Assembly

Assembly steps are as follows:

NOTICE:
The insulator shield must be replaced whenever the actuator assembly has been removed
from the EGR valve assembly. Reuse of the insulator shield will damage the
EGR assembly.
NOTICE:
The spline drive for the actuator assembly is keyed to ensure proper alignment with the
shaft on the valve assembly. When performing step 1 , do not force any components onto
the splined shaft. If excessive force is used, the splined shaft will be damaged.
 1. Install the hydraulic actuator assembly (5), heat shield (3), and new insulator shield
(2) onto the splined shaft (7) of the EGR valve assembly (1). See Figure "EGR
Hydraulic Actuator and Related Parts" .

1. EGR Valve 4. Splined Internal Drive

6. Bolts
Assembly
2. Insulator Shield 5. Hydraulic Actuator 7. Splined External
Assembly Shaft
3. Heat Shield

Figure 6. EGR Hydraulic Actuator and Related Parts

NOTICE:
When performing step 2 , apply torque evenly to the bolts to ensure that the EGR
valve assembly and hydraulic actuator assembly are not misaligned. Misalignment
will cause the assemblies to bind.

2. Install two bolts (6) through the hydraulic actuator assembly (5) to secure to the
EGR valve assembly (1). Torque bolts (6) to 24-28 N·m (18-21 lb·ft).

Section 16.2.5
Installation of Hydraulic EGR Valve

Installation steps are as follows:

1. Place a new gasket (3) onto the EGR cooler (5). See Figure "EGR Valve Assembly
and Related Parts" .

1. Nut 4. Stud
2. EGR Valve and Actuator Assembly 5. TSBF EGR Cooler
3. Gasket

Figure 7. EGR Valve Assembly and Related Parts

2. Properly align the EGR valve and actuator assembly (2) with studs (4) and install
onto the EGR cooler (5). See Figure "EGR Valve Assembly and Related Parts" .

Note: The EGR valve inlet tube should face the flywheel housing.

3. Secure the EGR valve and actuator assembly (2) to the EGR cooler (5) with nuts
(1). Torque the nuts to 22-26 N·m (16-19 lb·ft). See Figure "EGR Valve Assembly
and Related Parts" .
4. Install the oil inlet line fitting (3) and outlet line fitting (2) to EGR valve actuator.
Torque fittings to 24-28 N·m (18-21 lb·ft). See Figure "EGR Valve Oil Inlet line
and Oil Outlet Line" .
 1. EGR Valve and Hydraulic Actuator 3. Oil Inlet Line and
Assembly Fitting
2. Oil Outlet Line and Fitting

Figure 8. EGR Valve Oil Inlet line and Oil Outlet Line

5. Install the EGR valve assembly (11) to bellow (10) and secure with clamp (3).
Torque clamp (3) to 12 N·m (106 lb in). See Figure "Tube and Shell Bolted Flange
EGR Cooler and Related Parts" .
 7. Exhaust Manifold End
1. TSBF EGR Cooler
Section
2. EGR Hydraulic or Pneumatic Actuator 8. Exhaust Manifold Center
Assembly Section
9. Exhaust Manifold End
3. Clamp
Section
4. Upper Hot Pipe 10.Bellow
5. Gasket 11. EGR Valve Assembly
6. Stud 12. Gasket

Figure 9. Tube and Shell Bolted Flange EGR Cooler and Related Parts

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Section 16.3
Delivery Pipe

When the EGR valve is open, the exhaust gas is directed into the EGR cooler, through the
delivery pipe, and into the intake manifold.
Section 16.3.1
Removal of Delivery Pipe

Removal steps are as follows:

Note: Prior to performing the removal steps, ensure that the delivery tube is not hot.

PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.

1. Remove bolts securing the L-brackets to the camshaft gear cover. See Figure
"Delivery Pipe and Related Parts" .

1. Bolt 4. P-Clip 6. Delivery Pipe

2. L-Bracket 5. Nut 7. EGR Temperature Sensor
3. Hose

Figure 1. Delivery Pipe and Related Parts

2. Remove the bolt and nut from the two P-clips. See Figure "Delivery Pipe and
Related Parts" .
3. Remove the EGR Temperature Sensor from delivery pipe. See Figure "Delivery
Pipe and Related Parts" .
4. Remove the bolt that secures the P-clip and S-bracket to the exhaust manifold heat
shield. See Figure "Delivery Pipe and Related Parts" .

1. P-Clip 4. Hose 7. Exhaust Manifold Heat Shield

2. S-Bracket 5. Venturi Tube 8. Air Lines
3. Mid-Section 6. Clamp

Figure 2. Delivery Pipe and Related Parts

5. Disconnect the Delta P air lines from the venturi tube. See Figure "Delivery Pipe
and Related Parts" for the location of the air lines.
6. Loosen and remove the clamp that secures the venturi tube to the EGR cooler. See
Figure "Delivery Pipe and Related Parts" .
7. Loosen and remove the mixer clamp that secures the mixer to the intake manifold.
See Figure "Delivery Pipe and Related Parts" .
 1. Intake Manifold 3. Mixer 5. Clamps
2. Mixer Clamp 4. Delivery Pipe

Figure 3. Delivery Pipe and Related Parts

Section 16.3.2
Disassembly of Delivery Pipe

Disassembly steps are as follows:

1. Remove the clamps that secures the rubber hose which connects the two sections of
delivery pipe. See Figure "Delivery Pipe and Related Parts" .
2. Remove the rubber hose from the two sections of delivery pipe. See Figure
"Delivery Pipe and Related Parts" .

Section 16.3.2.1
Inspection of Delivery Pipe

Inspection steps are as follows:

1. Visually inspect the rubber hose for cracks and splits.

1. If the rubber hose is damaged, replace the component.
2. If the rubber hose is not damaged, reuse the component for assembly.
2. Visually inspect the hose clamps for damage.
1. If the hose clamps are damaged, replace as necessary.
2. If the hose clamps are not damaged, reuse the component for assembly.
3. Visually inspect the venturi section, mixer section, and mixer for damage.
 1. If the delivery pipe sections or mixer are damaged, replace sections as
necessary.
2. If the delivery pipe sections and mixer are not damaged, reuse the sections
for assembly.

Section 16.3.3
Assembly of Delivery Pipe

Assembly steps are as follows:

NOTICE:
Before the hose is installed on the delivery pipe ensure there are not any sharp edges
present that can cut the hose liner.
NOTICE:
If hose clamps have been removed from delivery pipe, they must be reinstalled prior to
hose installation.
NOTICE:
When installed on the hose, ensure the clamps are seated against the beads on the delivery
pipe mixer section, mid-section and venturi tube. Do not over stretch the clamp, open it (the
clamp) enough to clear hose. See figure "EGR Delivery Pipe Before Installation" and see
Figure "Delivery Pipe and Related Parts" .

1. Delivery Tube 3. Pipe Bead

2. Hose Clamp

Figure 4. EGR Delivery Pipe Before Installation

 1. Hose Clamp 2. Hose

Figure 5. Delivery Pipe and Related Parts

1. Install the rubber hose to the venturi-section of the delivery pipe and secure with
mixer clamp.
2. Insert the mixer section of the delivery pipe into the rubber hose and secure with the
clamp. Ensure that the top of the delivery pipe is horizontal. See Figure "Delivery
Pipe Mixer-Section and Related Parts" .
 1. Mixer 3. Clamp
2. Rubber Hose 4. Mixer Section

Figure 6. Delivery Pipe Mixer-Section and Related Parts

Section 16.3.4
Installation of Delivery Pipe

Installation steps are as follows:

1. Install mixer section of the delivery pipe to the intake manifold and secure with
band clamp. See Figure "Delivery Pipe and Related Parts" .

1. Intake Manifold 3. Mixer 5. Clamps

2. Mixer Clamp 4. Delivery Pipe

Figure 7. Delivery Pipe and Related Parts

2. Install the venturi tube to the EGR cooler and secure with clamp. See Figure "EGR
Cooler and Delivery Pipe" .
 1. Clamp 3. EGR Cooler
2. Venturi-Section 4. Air Lines

Figure 8. EGR Cooler and Delivery Pipe

3. Install Delta P air line fittings to the venturi tube. Torque fittings to 12 N·m (106
lb·ft). See Figure "EGR Cooler and Delivery Pipe" for location of air lines.
4. If removed, install rubber hose onto the venturi section and secure with clamp. See
Figure "Venturi Section and Related parts" .

1. P-Clip 4. Hose 7. Exhaust Manifold Heat Shield

2. S-Bracket 5. Venturi Tube 8. Air Lines
 3. Mid-Section 6. Clamp

Figure 9. Venturi Section and Related parts

5. Ensure that the venturi section of the delivery pipe is aligned with the mid section of
the delivery pipe. See Figure "Delivery Pipe and Related Parts" .

1. Venturi Section 3. Mid Section

2. Hose 4. Mixer Section

Figure 10. Delivery Pipe and Related Parts

6. Loosely install two gusseted L-brackets to the top of the camshaft gear cover. See
Figure "Delivery Pipe and Related Parts" .
 1. Bolt 4. P-Clip 6. Delivery Pipe
2. L-Bracket 5. Nut 7. EGR Temperature Sensor
3. Hose

Figure 11. Delivery Pipe and Related Parts

7. Loosely attach the delivery pipe to the gusseted L-brackets with two P-clips. See
Figure "Delivery Pipe and Related Parts" .
8. Loosely attach the delivery pipe to the forward exhaust manifold heat shield with a
P-clip and S-bracket. See Figure "Delivery Pipe and Related Parts" .

NOTICE:
Make sure that the P-clip is mounted behind the S-bracket.
Notice:
On some models the delivery tube is clipped to a bracket on the alternator. Ensure
correct alignment before torquing.

10. Torque the clamp at the delivery tube to intake mixer to 12 N·m (106 lb·in.).
11. Torque the clamp at the delivery tube to cooler to 12 N·m (106 lb·in).
12. Torque the L-Bracket bolts on the camshaft gear cover to 58-73 N·m (43-54 lb·ft).

Notice:
The camshaft gear cover is aluminum. Over tightening the bolt can strip threads in
the camshaft gear cover.

13. Torque the bolt and nut connecting the two P-clips to the gusseted L-brackets to 30-
38 N·m (22-28 lb·ft).
 14. Torque the bolt into the heat shield to 30-38 N·m (22-28 lb·ft).

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Section 16.4
EGR Rate Measurement System

The EGR Rate Measurement system provides DDEC with measurements resulting in EGR
flow rate prediction. The EGR Rate Measurement system consists of a venturi tube with a
Delta P Sensor and a Exhaust Gas Temperature Sensor. Pressure differential between the
venturi tube inlet, throat and along with exhaust gas temperature are converted to mass flow
rate in DDEC. The venturi tube is a component of the delivery pipe.

Section 16.4.1
Removal of EGR Rate Measurement System

Removal steps are as follows:

PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.

1. Remove connector at Delta P sensor.

2. Remove the four hose clamps (4) securing the Delta P tubes (5 and 9) to the Delta P
Sensor bracket (11). See Figure "Delta P Sensor and Related Parts" .
 1. Delta P Sensor 6. Delta P Tube Fittings 10. Nut
2. Stud 7. Venturi Tube 11. Bracket
3. Isolator 8. P-Clips 12. Thermostat Housing
4. Hose Clamp 9. Delta P Tube 13. Bolt
5. Delta P Tube

Figure 1. Delta P Sensor and Related Parts

3. Remove the two bolts securing the P-clips (8) and Delta P tubes (5 and 9) to the
exhaust manifold heat shield. See Figure "Delta P Sensor and Related Parts" .
4. Loosen and disconnect the Delta P tube fittings (6) from the venturi tube (7). See
Figure "Delta P Sensor and Related Parts" .
5. Remove the Delta P tubes (5 and9) from the hoses securing them to the sensor
mounting bracket (11). See Figure "Delta P Sensor and Related Parts" .
6. Remove two bolts (13) securing the Delta P Sensor (1) to bracket (11). See Figure
"Delta P Sensor and Related Parts" . Remove the Delta P Sensor.
7. Remove the three nuts (10) and six isolators (3) securing bracket (11) to thermostat
housing. See Figure "Delta P Sensor and Related Parts" . Remove the bracket.

Section 16.4.1.1
Inspection and Testing of EGR Rate Measurement System

Inspection steps are as follows:

1. The Delta P DDEC IV sensor using the Key On Engine Off test method. Refer to
the Series 60 Exhaust Gas Recirculation (EGR) Technicians Guide 7SE60. for the
test method.
1. If the sensor was diagnosed as defective, replace the sensor.
 2. If the sensor was diagnosed to not be defective, reuse the sensor.
2. The Delta P DDEC V sensor using the Key On Engine Off test method. Refer to the
Series 60 Exhaust Gas Recirculation (EGR) Technicians Guide 7SE60. for the test
method.
1. If the sensor was diagnosed as defective, replace the sensor.
2. If the sensor was not defective, reuse the sensor.
3. Visually inspect the isolators for damage.
1. If any of the isolators are damaged, replace as necessary.
2. If the isolators are not damaged, reuse the components for installation.
4. Visually inspect the Delta P tubes for damage.
1. If any of the tubes are damaged, replace as necessary.
2. If the tubes are not damaged, reuse the components for installation.

Section 16.4.2
Installation of EGR Rate Measurement System

Installation steps are as follows:

1. Install three isolators (3) over studs (2) of thermostat housing (12). See Figure
"Delta P Sensor and Related Parts" .
2. Install bracket (11) onto the thermostat housing (12). See Figure "Delta P Sensor
and Related Parts" .

1. Delta P Sensor 6. Fitting Nut 10. Nut

2. Stud 7. Venturi Tube 11. Bracket
3. Isolator 8. Clip 12. Thermostat Housing
4. Hose Clamp 9. Delta P Tube 13. Bolt
5. Delta P Tube
 Figure 2. Delta P Sensor and Related Parts

3. Install remaining three isolators (3) over studs (2) and secure bracket (11) and
isolators (3) to the thermostat housing with nuts.See Figure "Delta P Sensor and
Related Parts" . Torque nuts to 23-27 N·m (17-20 lb·ft).
4. Install the Delta P Sensor (1) to bracket (11) and secure with bolts (13). See Figure
"Delta P Sensor and Related Parts" . Torque bolts to 30-38 N·m (22-28 lb·ft).
5. Install the hose clamps (4) to the Delta P Sensor bracket (11). See Figure "Delta P
Sensor and Related Parts" .
6. Insert the Delta P tubes (5 and 9) to the hoses and secure with hose clamps (4). See
Figure "Delta P Sensor and Related Parts" .
7. Connect the Delta P tubes (5 and 9) to the venturi tube (7). See Figure "Delta P
Sensor and Related Parts" .
8. Secure the P-clips (8) to the exhaust manifold and secure with bolts. See Figure
"Delta P Sensor and Related Parts" . Torque the bolts to 30-38 N·m (22-28 lb·ft).
9. Torque Delta P tube fitting nuts (6) to 24-30 N·m (18-22 lb·ft). Connect Delta P
sensor connector at sensor.

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Section 16.5
DDEC V Varible Pressure Output Device

The Variable Pressure Output Device (VPOD) regulates the Variable Nozzle Turbo (VNT).
Input values from the ECM/ECU regulates the VPOD air pressure which allows the
VNT vanes to change position during engine operation. The VPOD also interfaces with
other engine system components.

Section 16.5.1
Removal of Variable Pressure Output Device

Removal steps are as follows:

PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.

1. Remove bolt (3) securing air line to oil cooler. See Figure "VPOD and Related
Parts"
2. Disconnect the air line fittings and remove the air line (4) from the VPOD assembly
(1) and VNT actuator (5). See Figure "VPOD and Related Parts" .

1. VPOD Assembly 3. Bolt 5. VNT Actuator

2. Clip 4. Air Line

Figure 1. VPOD and Related Parts

3. Unplug the sensor harness (2) from the VPOD assembly (4). See Figure "VPOD
and Related Parts" .

1. Bolt 3. Stud
 2. Sensor Harness 4. VPOD Assembly

Figure 2. VPOD and Related Parts

4. Remove the bolts (1) and stud (3) securing the VPOD assembly (4) with bracket to
the engine block. See Figure "VPOD and Related Parts" . Remove the VPOD
assembly.

Section 16.5.1.1
Inspection and Testing of VPOD

Inspection steps are as follows:

1. To test the VPOD, refer to the Exhaust Gas Recirculation System Basic Checks
Section found in the DDEC V Single ECU Troubleshooting Guide , 6SE565.
1. If the VPOD is defective, replace the component.
2. If the VPOD is not defective, reuse the component for installation.
2. Visually check the sensor harness for damage.
1. If the harness is damaged, repair as necessary and refer to the Wiring and
Wires and Conduit and Loom sections found in the DDEC V Single ECU
Troubleshooting Guide , 6SE565.
2. If the harness is not damaged, reuse the harness for installation.

Section 16.5.2
Installation of Variable Pressure Output Device

Installation steps are as follows:

1. Align VPOD assembly (4) with bracket to the engine block and secure with stud (3)
and bolts (1). See Figure "VPOD and Related Parts" . Torque the M10 bolt and M10
stud to 58-73 N·m (43-54 lb·ft) and the M8 bolt to 30-38 N·m (22-28 lb·ft).
 1. Bolt 3. Stud
2. Sensor Harness 4. VPOD Assembly

Figure 3. VPOD and Related Parts

2. Connect the sensor harness (2) to the VPOD assembly (4). See Figure "VPOD and
Related Parts" .
3. Connect air line (4) fittings to the VPOD assembly (1) and to the VNT actuator (5).
See Figure "VPOD and Related Parts" . Torque the fittings to 12 N·m (106 lb·ft).
4. Install bolt (3) and secure air line fitting and clip to oil cooler Torque bolt to 30–38
Nm (22–28 lb ft).See Figure "VPOD and Related Parts" .
 1. VPOD Assembly 3. Bolt
2. Clip 4. Air Line

Figure 4. VPOD and Related Parts

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Section 16.6
DDEC IV Varible Pressure Output Devices

DDEC IV engines use two VPODs which control the VNT and EGR valve. During engine
EGR operation, the VPODs provide modulated air pressure to the pneumatic actuators
which change the position of the VNT vanes and the position of the EGR valve.

Section 16.6.1
Removal of Variable Pressure Output Devices

Removal steps are as follows:

1. Disconnect the air line (7) fitting from the VPODs (6) and VNT actuator (8). See
Figure "VPODs Air Supply Lines and Related Parts" .

1. Bolt 3. EGR Valve Assembly 5. Clamps 7. Air Line

 2. Air Line Fitting 4. Air Line 6. VPODs 8. VNT Actuator

Figure 1. VPODs Air Supply Lines and Related Parts

2. Disconnect the air line (4) fittings from the EGR valve assembly (3) and the VPODs
(6). See Figure "VPODs Air Supply Lines and Related Parts" .
3. Disconnect the sensor harness (2) from the VPODs (4). See Figure "VPODs and
Related Parts" .

1. Bolt 3. Stud
2. Sensor Harness 4. VPODs

Figure 2. VPODs and Related Parts

4. Remove the two bolts (1) and stud (3) that secure the VPODs (4) to the engine
block. See Figure "VPODs and Related Parts" . Remove the VPODs.
Section 16.6.1.1
Inspection of Variable Pressure Output Devices

Inspection steps are as follows:

1. To test the VPODs, refer to the Exhaust Gas Recirculation System Basic Checks
Section found in the DDEC V Single ECU Troubleshooting Guide , 6SE497.
1. If the VPOD is defective, replace the component.
2. If the VPOD was not defective, reuse the component for installation.
2. Visually check the sensor harness for damage.
1. If the harness is damaged, repair as necessary and refer to the Wiring and
Wires and Conduit and Loom sections found in DDEC IV Single ECU
Troubleshooting Guide , 6SE497.
2. If the harness is not damaged, reuse the harness for installation.

Section 16.6.2
Installation of Variable Pressure Output Devices

Installation steps are as follows:

1. Align the VPODs (4) brackets to the engine block and secure with two bolts (1) and
stud (3). See Figure "VPODs and Related Parts" . Torque the M10 bolt and M10
stud to 58-73 N·m (43-54 lb·ft) and the M8 bolt to 30-38 N·m (22-28 lb·ft).
 1. Bolt 3. Stud
2. Sensor Harness 4. VPODs

Figure 3. VPODs and Related Parts

2. Connect the sensor harness (2) to the VPODs (4). See Figure "VPODs and Related
Parts" .
3. Connect air line (7) fitting to the VPODs (6) and VNT actuator (8). See Figure
"VPODs Air Supply Lines and Related Parts" .
 1. Bolt 3. EGR Valve Assembly 5. Clamps 7. Air Line
2. Air Line Fitting 4. Air Line 6. VPODs 8. VNT Actuator

Figure 4. VPODs Air Supply Lines and Related Parts

4. Connect air line (4) fittings to the EGR valve assembly (3) and to the VPODs (6).
See Figure "VPODs Air Supply Lines and Related Parts" .