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Home›Repair guides›Detroit Diesel›EGR Connector Pipe Installation

Detroit Diesel — EGR Connector Pipe Installation

Installation · EGR connector pipe and throttle shutoff valve

From a Detroit Diesel service manual — check it applies to your exact model before use.

Before you start

  • PERSONAL INJURY: To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.
  • Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.
  • NOTICE: To avoid connector pipe damage, the Fey rings must be installed according to directions.

Procedure

  1. Loosen and remove the outside nut on the outside face of the stud bracket. See Figure 1.
  2. Remove the bolt from the positioning clamp holding the gas inlet pipe to the throttle shutoff valve and remove the clamp. See Figure 2.
  3. Gently pull the gas inlet pipe from the center piece of the exhaust manifold and the throttle shutoff valve. See Figure 3.
  4. Remove the air supply line to the throttle shutoff valve actuator. See Figure 4.
  5. Remove the two throttle shutoff valve mounting bolts and then the throttle shutoff valve. See Figure 5.
  6. Slide out the EGR connector pipe from the EGR cooler.
  7. Install one wave spring into the EGR cooler inlet with the flat side facing out. See Figure 6.
  8. Install one seal ring into the EGR cooler inlet against the flat side of the wave spring. See Figure 6.
  9. Inspect the connector pipe assembly: four grooves (two per end), two Fey rings per groove (eight total), staggered 180 degrees within each groove and 90 degrees at each end.
  10. Install the new EGR connector pipe assembly into the EGR cooler.
  11. Install the other wave spring into the throttle shutoff valve with the flat side facing out, then the other seal ring against the flat side. See Figure 6.
  12. Slide the throttle shutoff valve onto the new EGR connector pipe assembly. See Figure 6.
  13. Install the two throttle shutoff valve mounting bolts and torque to 35 N·m (26 lb·ft); install the air supply line and torque the nut to 25 N·m (18 lb·ft).
  14. Install the gas inlet pipe into the exhaust manifold center section and the throttle shutoff valve; install the positioning clamp and hand tighten the bolt.
  15. Install the outside nut on the stud bracket and torque to 25 N·m (18 lb·ft); verify stud length is 219 mm (8.62 in) and adjust if needed; torque the positioning clamp to 12 N·m (9 lb·ft); start and ru

Specs & values

  • Throttle shutoff valve mounting bolts: 35 N·m (26 lb·ft)
  • Air supply line nut: 25 N·m (18 lb·ft)
  • Outside nut on stud bracket: 25 N·m (18 lb·ft)
  • Positioning clamp: 12 N·m (9 lb·ft)
  • Stud length: 219 mm (8.62 in)

Source: Detroit Diesel service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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