Egr cooler replacement1

DVolvo Trucks North AmericaGreensboro, NC USA

Date Group No. Page

12.2006 254 23 1(30)

Trucks

EGR CoolerReplacement

D16F

EGR Cooler Replacement

W2005772

This information covers the proper replacement procedure for the EGR cooler onthe Volvo D16F engine.

For information on the design and function of the EGR system, refer to ServiceInformation, group 25.

Contents• “Special Tools” page 2

• “EGR Cooler, Replacement” page 3

• “EGR Cooler, Cleaning” page 27

Note: Information is subject to change without notice.Illustrations are used for reference only, and may differ slightly from the actual engineversion. However, key components addressed in this information are represented asaccurately as possible.

PV776-20176590 USA22050.ihval

DServ ice Bulletin 12.2006 254 23 2(30)

Special ToolsFor special tools ordering information, refer to Tool Information, group 08.

9996049Drain Hose for Coolant

85108575Turbo Lifting Tool

DBT2V700Coolant Extractor


2547-03-02-01EGR Cooler, Replacement

See also:

• “EGR Cooler Replacement” page 1

You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.

Not Included:

• “EGR Cooler, Cleaning” page 27

Special tools: 9996049, 85108575,DBT2V700

Removal1Apply the parking brake and place the shift leverin neutral.

2

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Turn the master switch OFF (if equipped) or disconnectthe batteries by disconnecting the negative battery cable.

3Connect the coolant extractor to the drain fitting at thebottom of the radiator and drain the coolant.

Note: An alternate method is to connect the drainhose to the drain fitting and drain the coolant into anapproved container.

DBT2V700, 9996049


4

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1-Two (2) fenderextender bolts [rear,at bracket]

4-One (1) splashguard bolt [lower, toframe]

2-Two (2) fenderextender bolts [atbrace]

5-Two (2) splashguard bolts [upperbrace]

3-One (1) fenderextender brace athood release [boltand nut]

Dependent upon chassis, remove the splash guard andthe fender extender as an assembly, if required.

5

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Remove the air filter housing by first disconnecting the airrestriction gauge connector.

6

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Remove the clamps securing the wiring harness to theair filter housing.


7

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Loosen the clamp and remove the air compressor freshair pipe from the main fresh air pipe.

8

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Disconnect the air temperature sensor connector from thesensor. Cut the tie strap and disengage the lock tab. Also,remove the bolt securing the temperature sensor harnessP-clamp to the fresh air pipe for the turbocharger.

9

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Loosen the clamp of the main fresh air pipe at theturbocharger. Disconnect the fresh air pipe fromthe turbocharger.

10

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Remove the two bolts at the top of the air filter housing.


11

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Remove the air filter housing and the main fresh air pipeas an assembly.

12Remove the lower charge air pipe from the turbocharger.

13

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Release the actuator and turbocharger speed sensorwiring harnesses by cutting the nylon tie straps to free theharnesses. Disconnect the connectors located on theright side of the engine above the oil filter housing. Matchmark the connectors for reassembly purposes.

14

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Disconnect the coolant inlet and outlet lines from theturbocharger actuator.


15

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Disconnect the coolant line from the top of theturbocharger bearing housing.

16

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Disconnect the turbocharger coolant line that connectsto the oil cooler cover.

17

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Disconnect the oil supply line that connects from thebottom of the turbocharger bearing housing to theoil filter housing.


18

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Remove the two small capscrews securing the oilreturn/drain back pipe to the bottom of the turbochargerbearing housing and disconnect the pipe from the spacerblock. Collect the spacer block. Discard the gasket andO-ring from the spacer block.

19

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Loosen the clamp at the turbocharger exhaust pipe andslide the exhaust injector pipe backward slightly to allowthe turbocharger to be free of the exhaust system.

20

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Remove the bolt/plug at the top of the turbochargerbearing housing and install the turbocharger lifting tool85108575 into the threaded hole.

85108575


21

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Support the weight of the turbocharger using a mobilefloor crane such as OTC 16-1815 or equivalent cranecapable of safely lifting the weight of the turbocharger.Remove all four turbo flange mounting nuts and spacers.

22

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With the aid of an assistant, lower the turbochargeraway from the exhaust manifold studs and remove itfrom the engine.

23Place the turbocharger on a suitable support. Plugthe turbo oil lines and outlet openings to preventcontamination. Install the cover on the turbo intake andexhaust openings to prevent foreign material frompossibly becoming lodged in the turbine wheels.


24

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Remove the Allen head fasteners and bolts securing theupper portion of the EGR hot pipe shield and removethe upper shield.

25

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Remove the bolts securing the lower portion EGR valveheat shield and remove the shield.

26

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Loosen both high temperature V-clamps from the EGRhot pipe by removing the nuts from the T-bolts. Free theclamps from the EGR hot pipe flange.

Note: EGR V-clamps on the hot pipe are one time useonly. Replace the V-clamps with new at installation.


27

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Remove the EGR hot pipe from between the EGR valveand the EGR gas cooler.

28

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Remove the special high temperature gaskets fromthe EGR valve end of the hot pipe and the EGR gascooler. Discard the gaskets.

29

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Remove the fuel line support clamp from the exhaustinjector (HCI). The clamp is located at the bottom ofthe exhaust pipe.


30

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Remove the fuel line from the exhaust injector (HCI).

31

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Remove the coolant inlet and outlet lines that connect tothe exhaust injector (HCI).

32Reposition the exhaust injector (HCI) pipe away from theEGR cooler to allow access to the cooler connections.

33

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Disconnect the EGR cooler straps by removing the topbolts and lower nuts with spacers.


34

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Remove the capscrews securing the coolant hard pipeclamps at the oil cooler cover port and the EGR coolerand remove the clamps.

35

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Remove the clamps securing the coolant hose from theEGR cooler to the thermostat housing and slide the hoserearward. Also, remove the clamps securing the EGRcool gas hose to the delta pressure venturi pipe andslide the hose forward. Remove both hoses and discard.These hoses should not be reused.

Note: Inspect the EGR gas hose connection pipes forhose residue and clean connections as necessary.

36Remove the static fill pipe to the EGR cooler.

37

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Pull the EGR cooler outward and at same time, slideit backward to free the coolant hard pipe from the oilcooler cover. Remove the EGR cooler from the leftside of the engine.


38

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Using a small pick, remove the O-ring from both ends ofthe EGR cooler coolant hard pipe.

InstallationNote: The EGR cooler may require cleaning beforeinstallation; see “EGR Cooler, Cleaning” page 27.

1

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Place a new O-ring seal on both ends of the EGR coolerhard pipe and lubricate with a coating of fresh antifreeze.Slide the hard coolant pipe into the top port of the EGRcooler. Ensure the O-ring on the coolant hard pipe is notpinched during installation.

Note: Use a new O-ring on the pipe.

2Slide the EGR cooler straps onto the studs. This stepmust be completed before positioning the EGR cooleronto the engine brackets.


3

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Position the EGR cooler onto the cast brackets located onthe oil cooler cover and at same time, slide it forward toconnect the coolant hard pipe with the oil cooler covercoolant port. Ensure the O-ring on the coolant hard pipeis not pinched during installation.

Note: Use a new O-ring on the pipe.

4Install the spacers and nuts onto the bottom studs forthe EGR cooler straps. Only hand tighten the nutssnug at this time.

5

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Install the EGR cooler strap top bolts and hand tightensnug.

6Torque the nuts located on the bottom of the EGR coolerstraps to specification before tightening the bolts locatedat the top of the straps. Torque-tighten the bottom nuts to24 ± 3 Nm (18 ± 2 ft-lb).

24 ± 3 Nm(18 ± 2 ft-lb)

7Torque-tighten the EGR strap bolts located at the top to12 ± 2 Nm (110 ± 1 in-lb).

12 ± 2 Nm(110 ± 1 in-lb)


8

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Install a new coolant hose between the EGR cooler tothe thermostat housing and slide the hose forward to itsoriginal position. Also, install a new EGR cool gas hoseto the delta pressure venturi pipe and slide the hoserearward to its original position. Secure both hoses withthe original clamps tightened securely.

Note: It is important to install new hoses at both locationsfor the EGR cooler.

9

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Install the coolant hard pipe clamps at the oil cooler coverport and the EGR cooler port. Install the capscrewssecuring the clamps and tighten securely.

10Install the static fill pipe to the EGR cooler. Torque-tightento 10 ± 2 Nm (7 ± 1 ft-lb).

10 ± 2 Nm(7 ± 1 ft-lb)


11

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Install new special high temperature gaskets into theEGR valve end of the hot pipe and the inlet of the EGRgas cooler. Ensure the gasket lays flat against theflange surfaces.

12

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Hook the upper V-clamp over the EGR valve flange.Next, place the remaining V-clamp over the bellowson the hot pipe.

Note: Do not reuse clamps. Install new clamps andsealing rings.

13Lubricate both the flange on the EGR cooler inlet and theflange on the EGR hot pipe with flesh engine oil. Thislubrication will aid in V-clamp installation.

14Position the EGR hot pipe between the EGR valve andthe EGR gas cooler. Be sure the flange engages properly.While holding the hot pipe in position, slide the upperV-clamp over the flange and tighten until snug. Next, slidethe lower V-clamp over the flange of the EGR coolerand tighten the clamp until snug.

15Visually inspect that the flange is still seated in the EGRcooler. The flange needs to be concentric with the cooler.


16Position the V-clamps so that the T-bolts will clear bothheat shields. Apply anti-seize to the threads of the T-boltsand tighten to specifications. Torque-tighten to 20± 3 Nm (15 ± 2 ft-lb).

Note: After reaching the specified torque, inspect theV-clamps to ensure that no portion of the clamp has“bottomed out”.

20 ± 3 Nm(15 ± 2 ft-lb)

17

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Position the lower portion of the EGR valve heat shieldover EGR hot pipe and secure with bolts. Tightenfasteners to specifications.

18

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Position the upper portion of the EGR hot pipe shield andinstall the Allen head fasteners and bolts securing theupper portion of the EGR hot pipe shield to the cylinderblock. Tighten fasteners to specifications.

19Clean the contact surface on the exhaust manifold andthe oil return/drain back pipe and spacer block.


20Remove the plugs from the turbo oil lines and outletopenings used to prevent contamination. Remove thecovers used on the turbo intake and exhaust openings.

21

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Replace the turbocharger-to-manifold metal gasketand install it onto the two studs of the turbochargerexhaust opening.

22

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Support the weight of the turbocharger using a mobilefloor crane such as OTC 16-1815 or equivalent cranecapable of safely lifting the weight of the turbocharger.With the aid of an assistant, position the turbochargeragainst the exhaust manifold and align the two studsof the turbocharger with the two studs of the exhaustmanifold.

23

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Install the turbocharger flange nuts and spacers to theexhaust manifold and torque-tighten to the specificationof 135 Nm (100 ft-lb). Nuts should be tightened inthe sequence shown.

135 Nm(100 ft-lb)


24Remove the hoist and special lifting tool 85108575.Reinstall the bolt/plug in the turbo lift threaded hole whichis located in the top of the bearing housing.

25

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Position a new lubricated O-ring and gasket on the oilreturn/drain back spacer block and install the turbochargeroil return/drain back pipe with spacer to the bottomof the turbo. Secure using the two small capscrews.Torque-tighten the capscrews to 24 ± 4 Nm (18 ± 3 ft-lb).

24 ± 4 Nm(18 ± 3 ft-lb)

26

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Install the turbocharger oil supply line to the bottom fittingof the turbo bearing housing and tighten the fittings.

CAUTION

Before starting the engine after turbochargerreplacement, make sure the turbocharger is pre-filledwith clean engine oil. Starting the engine without oilpressure and a “dry” turbocharger can damage theturbocharger bearings.

27

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Install the coolant line that connects from the rear ofthe turbocharger to a fitting on the oil cooler and tightenthe fitting.


28

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Install the coolant line that connects to the fitting at thetop of the turbocharger bearing housing and tightenthe fitting. This coolant line also branches off theturbocharger actuator top coolant fitting.

29

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Install the coolant lines that connect to the fittings at thetop and bottom of the turbocharger actuator and tightenthe fittings.

30

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Reconnect the turbocharger actuator and turbochargerwheel speed sensor wiring harness. Ensure theconnectors are reconnected in the same positions asmarked at disassembly and position the connector withthe flat side toward the flat in the bracket. Reinstall thecable clamp on the oil filter housing and using the properhigh temperature ties, secure the wiring harness to itselfand the turbocharger drain pipe.


31

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Position the exhaust injector pipe against the exhaust porton the turbocharger and install a new clamp from theexhaust pipe to the turbocharger. Align the cast in matchmarks on the exhaust pipe with the turbocharger andtighten the clamp to secure in this position.

32

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Install the coolant inlet and outlet lines that connect to theexhaust injector (HCI).

33

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Install the fuel line onto the exhaust injector (HCI).


34

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Install the fuel line support clamp onto the exhaustinjector (HCI). The clamp is located at the bottom ofthe exhaust pipe.

35

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Position the main fresh air pipe and the filter housingagainst the cab.

36

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Install the two bolts at the top of the air filter housing.

37Install the main fresh air pipe to the turbocharger. Tightenthe clamps.


38

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Install the air temperature sensor connector to thesensor. Insert the connector lock tab, push in placeand secure with a tie strap. Also, install the P-clampsecuring the temperature sensor harness to the fresh airpipe for the turbocharger.

39

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Install the air compressor fresh air pipe to the main freshair pipe, position the clamp and tighten to secure.

40

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Install the filter restriction gauge wiring harness to the airfilter housing and tighten the clamps.


41

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Connect the air restriction gauge electrical harnessconnector.

42Reinstall the charge air pipe to the turbocharger.

43

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Turn the master switch ON (if equipped) or connect thebatteries by reconnecting the negative battery cable.

44

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1-Two (2) fenderextender bolts [rear,at bracket]

4-One (1) splashguard bolt [lower, toframe]

2-Two (2) fenderextender bolts [atbrace]

5-Two (2) splashguard bolts [upperbrace]

3-One (1) fenderextender brace athood release [boltand nut]

Install the splash guard and the fender extender as anassembly, if removed for access.

45Check the engine oil level and replenish as necessarywith approved engine oil.


46

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Using coolant extractor DBT2V700, fill the system withapproved coolant per specifications.

DBT2V700

47Start the engine and check for proper operation. Checkfor coolant, oil and air leaks. Check the coolant and oillevel, and refill as necessary.

CAUTION

Before starting the engine after turbochargerreplacement, make sure the turbocharger is pre-filledwith clean engine oil. Starting the engine without oilpressure and a “dry” turbocharger can damage theturbocharger bearings.


EGR Cooler, CleaningSee also:

• “EGR Cooler Replacement” page 1

You must read and understand the precautions andguidelines in Service Information, group 20, "GeneralSafety Practices, Engine" before performing thisprocedure. If you are not properly trained and certifiedin this procedure, ask your supervisor for trainingbefore you perform it.

1

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Remove the EGR cooler from the engine, then separatethe coolant pipe from the cooler.


2

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Place the cooler in the parts washer and fill withDyna 143 cleaning solvent. Let soak for one hour.

3

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Hang the cooler.


4

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Steam clean the cooler from the inlet end first, until thewater clears up.

Note: Avoid contact from steam and air nozzle to EGRfins during cleaning operation. This may damage theEGR fins.

5

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Steam and soot should flow out from the lower end ofthe cooler.

6Turn the cooler over and steam clean from the outlet end.

7Steam clean the cooler from the outlet end until thewater clears up.


8

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Using a shop air blower, from the inlet end, blow air intothe cooler until all the water is out. Do this with the coolerhanging up so that the leftover water can flow downward.

9Using a shop air blower, from the outlet end, blow air intothe cooler until all the water is out. Do this with the coolerhanging up so that the leftover water can flow downward.

10With the EGR cooler completely clear of water andcleaning solution, reinstall the coolant pipe with newO-rings and install the cooler back on the engine.

Egr cooler replacement1

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