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Service LetterPRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST GAS RECIRCULATION (EGR)

VALVE ON CERTAIN CT660 ON HIGHWAY TRUCKS

Media Number -TEBE0420-00 Publication Date -11/11/2013 Date Updated -11/11/2013

Caterpillar: Confidential Yellow

TEBE0420-00

11Nov2013

U-555

Before/AfterPRODUCT SUPPORT PROGRAM FOR REPLACING EXHAUST

GAS RECIRCULATION (EGR) VALVE ON CERTAIN CT660

ON HIGHWAY TRUCKS

7000 PS44078

NOTE:This Program must be administered either before or after

failure. In either case the decision whether to apply the

Program is made by the dealer. When reporting the repair, use

"PS44078" as the Part Number and "7755" as the Group Number. If

administered before failure, use "56" as the Warranty Claim

Description Code and "T" as the SIMS Description code. If chrismk2Caterpillar: Confidential Yellow

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12/3/2013https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/siswe...

SB-10054088-6635

administered after failure, use "96" as the Warranty Claim

Description Code, and "Z" as the SIMS Description Code.

NOTE:The information supplied in this service letter may not be valid

after the termination date of this program. Do not perform the

work outlined in this Service Letter after the termination date

without first contacting your Caterpillar product analyst.

TERMINATION DATE

30Nov2015

PROBLEM

The existing Exhaust Gas Recirculation (EGR) Valve can fail on certain

on certain CT660 On Highway Trucks. If the existing EGR Valve fails it

can cause various performance problems.

AFFECTED PRODUCT

Model Identification Number

CT660 TKL00100-00161, 164-169, 178

TRK00100, 103-179, 181-284, 286-288, 290-314, 316-344,

346-419, 421-481, 485-486, 507, 525, 528-534, 536, 546,

568

TSW00100

TSY00100

PARTS NEEDED

Qty

Part Number Description

1 3809393 KIT-EGR VALVE

chrismk2Caterpillar: Confidential Yellow



1 3862541 KIT-EGR MODULE

(After Failure

Only)

1 4196185 KIT-EGR TUBE OUT

1 4206074 KIT-EGR TUBE

In order to allow equitable parts

availability to all participating dealers,

please limit your initial parts order to

not exceed 23% of dealership population.

This is an initial order recommendation

only, and the ultimate responsibility for

ordering the total number of parts needed

to satisfy the program lies with the

dealer.

ACTION REQUIRED

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age

whichever comes

first

Caterpillar Dealer Suggested Customer Suggested

Parts %Labor

Hrs%Parts %

Labor

Hrs%Parts %

Labor

Hrs%

0-200000 miles,

0-30 mo

100.0% 100.0% 0.0% 0.0% 0.0% 0.0%

NOTE: This is a 3.8-hour job

Note: An additional 0.5 hour is allowed to replace the High-Temp

(HT) EGR cooler if it fails inspection according to step 20 in the

disassembly portion of the Rework Procedure. After Failure only.




PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty

parts handling.

Rework Procedure

Exhaust Gas Recirculation (EGR) Valve Replacement

WARNING: Read all safety instructions in the “Safety Information”

section of the Engine

Service Manual or Engine Diagnostic Manual to prevent personal injury or

death.

WARNING: To prevent personal injury or death, shift transmission to park

or neutral, set

parking brake, and block wheels before doing diagnostic or service

procedures.

WARNING: If the vehicle must be raised, do not work under the vehicle

supported only by

jacks. Jacks can slip or fall over, potentially resulting in property

damage, personal injury, and/or

death.

WARNING: Always wear safe eye protection when performing vehicle

maintenance. Failure

to do so may result in serious eye injury.

WARNING: Keep flames or sparks away from vehicle and do not smoke while

servicing

the vehicle’s batteries. Batteries expel explosive gases. Failure to do

so may result in property

damage, personal injury, and/or death.

WARNING: Remove the ground cable from the negative terminal of the

battery box before

disconnecting any electrical components. Always connect the ground cable

last. Failure to do so

may result in property damage, personal injury, and/or death.

EGR VALVE REPLACEMENT PROCEDURE

1. Turn vehicle wheels to right and remove engine cover. chrismk2Caterpillar: Confidential Yellow



2. Using Coolant Management Tool , drain cooling system.

3. Disconnect Engine Coolant Temperature sensor 1 (ECT1) (Image 1.1.1,

Item 2).

Image1.1.1

Image 1.1.1 Engine Coolant Temperature (ECT) Sensor.

1. Engine harness

2. ECT1 sensor

4. Disconnect EGR valve engine harness connector (Image 1.2.1, Item 2)

Image1.2.1

Image 1.2.1 EGR Valve Engine Harness Connector.

1. Engine harness

2. EGR valve engine harness connector

5. Cut and remove wire tie (Image 1.3.1, Item 1) near EGR valve

electrical connector (Image 1.3.1, Item 2).




Image1.3.1

Image 1.3.1 EGR Valve Electrical Connector.

1. Wire tie

2. EGR valve electrical connector

6. Remove engine harness guide (Image 1.4.1, Item 1) from bolt (Image

1.4.1, Item 2).

Image1.4.1

Image 1.4.1 Engine Harness Guide.

1. Engine harness guide

2. Bolt (not shown, located behind engine harness guide)

7. Remove engine harness guide (Image 1.5.1, Item 1) from bolt (Image

1.5.1, Item 2).

Image1.5.1



2. Bolt

3. Engine harness

8. Remove cab heater supply tube support brackets (Image 1.6.1, Item 1)

from EGR cooler (Image 1.6.1, Item 2)




Image1.6.1

Image 1.6.1 Cab Heater Supply Tube Brackets.

1. Cab heater supply tube brackets

2. EGR cooler

9. Disconnect cab heat tube (Image 1.7.1, Item 1) from heat tube nipple

(Image 1.7.1, Item 2) on coolant manifold.

Image1.7.1

Image 1.7.1 Cab Heat Tube.

1. Cab heat tube

2. Heat tube nipple

10. Remove hydrocarbon injector (HCI) coolant supply tube nut (Image

1.8.1, Item 1) from coolant manifold (Image 1.8.1, Item 2).

Image1.8.1chrismk2




Image 1.8.1 Coolant Manifold.

1. HCI coolant supply tube nut

2. Coolant manifold

CAUTION: To prevent component damage, do not bend fuel supply line.

11. Remove and cap HCI fuel supply line (Image 1.9.1, Item 2) and inlet

nut (Image 1.9.1, Item 1).

Image1.9.1

Image 1.9.1 HCI Fuel Supply Line.

1. HCI fuel inlet nut

2. HCI fuel supply line

12. Remove EGR inlet tube heat shield (Image 1.10.1, Item 1), remove one

heat-resistant bolt (Image 1.10.1, Item 2),and remove three bolts (Image

1.10.1, Item 3).

Image1.10.1

Image 1.10.1 EGR Inlet Tube Heat Shield.

1. EGR inlet tube heat shield

2. Heat-resistant bolt

3. Bolt (3)

NOTE: Place drip pan under truck to prevent coolant from leaking on chrismk2




ground.

13. Remove coolant manifold (Image 1.11.1, Item 1), remove two bolts

(Image 1.11.1, Item 2), and one stud bolt (Image 1.10.1, Item 3).

Image1.11.1


1. Coolant manifold

2. Bolt (2)

3. Stud bolt

CAUTION: To prevent engine damage, extension tubes should be handled

with care.

14. Remove EGR inlet tube (Image 1.12.1, Item 1), and remove four heat-

resistant bolts and two gaskets (Image 1.12.1, Item 2). Do not reuse the

bolts and gaskets.

Image1.12.1

Image 1.12.1 EGR Inlet Tube (Outside).

1. EGR inlet tube (outside)

2. Heat-resistant bolt (4) and gasket (2)

15. Remove EGR inlet tube (Image 1.13.1, Item 1), remove two heat-

resistant bolts and gasket (Image 1.13.1, Item 2), and remove two heat-

resistant bolts and gasket (Image 1.13.1, Item 3). Do not reuse the

bolts and gaskets. chrismk2Caterpillar: Confidential Yellow



Image1.13.1

Image 1.13.1 EGR Inlet Tube (Inside).

1. EGR inlet tube (inside)

2. Heat-resistant bolt (2) and gasket

3. Heat-resistant bolt (2) and gasket

16. Place cap on rear exhaust manifold outlet (Image 1.14.1, Item 1).

Image1.14.1

Image 1.14.1 Rear Exhaust Manifold Outlet.

1. Rear exhaust manifold outlet cap

17. Remove EGR valve coolant supply tube nut (Image 1.15.1, Item 1) and

position tube away from valve.


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Image1.15.1

Image 1.15.1 EGR Valve.

1. EGR valve coolant supply tube nut

2. EGR valve

18. Remove EGR heat shield (Image 1.16.1, Item 1) and remove two bolts

(Image 1.16.1, Item 2).

Image1.16.1

Image 1.16.1 EGR Heat Shield.

1. EGR heat shield

2. Bolt (2)

19. Remove nine heat-resistant bolts (Image 1.17.1, Item 3) and the EGR

valve (Image 1.17.1, Item 3). Position EGR valve coolant return tube

assembly (Image 1.17.1, Item 2) out of the way.




Image1.17.1


1. EGR valve

2. EGR valve coolant return tube assembly

3. Heat-resistant bolt (9)

4. EGR valve coolant supply tube (previously removed)

NOTE: Do not reuse gasket after removal of the EGR valve.

20. Inspect High-Temp (HT) EGR cooler inlet for damage (Image 1.18.1,

Item 1). If HT EGR cooler is damaged, replace HT cooler.

Image1.18.1

Image 1.18.1 High-Temp (HT) EGR Cooler Inlet.

1. HT EGR cooler inlet damage

NOTE: EGR cooler inlet may have internal rust due to condensation (Image

1.19.1). This condensation or rust is normal and does not require

replacement of high-temp EGR cooler.




Image1.19.1

Image 1.19.1 EGR Cooler Inlet.

1. EGR cooler inlet internal rust

1. Install EGR valve (Image 1.20.1, Item 1) with nine new M8 x 30 heat-

resistant bolts (Image 1.20.1, Item 3) and finger tighten. Install EGR

valve coolant return tube assembly (Image 1.20.1, Item 2).

NOTE: Use new gasket when replacing EGR valve.

Image1.20.1


1. EGR valve

2. EGR valve coolant return tube assembly

3. Heat-resistant bolt (9)

4. EGR valve coolant supply tube

2. Torque four new M8 x 30 heat-resistant bolts to 45 lb-in (5 Nm) in

bolt tightening sequence 1 (Image 1.21.1).




Image1.21.1

Image 1.21.1 Bolt Tightening Sequence 1.

3. Torque all nine M8 x 30 heat-resistant bolts to 12 lb-ft (16 Nm) in

bolt tightening sequence 2 and 3 (Image 1.22.1). Repeat sequence and

torque to 18 lb-ft (24 Nm).

Image1.22.1

Image 1.22.1 Bolt Tightening Sequence 2 and 3.

4. Install EGR heat shield (Image 1.23.1, Item 1), two M8 x 12 bolts

(Image 1.23.1, Item 2), and torque to 18 lb-ft (24 Nm).

Image1.23.1

Image 1.23.1 EGR Heat Shield.

1. EGR heat shield

2. M8 x 12 bolt (2)

5. Install the EGR valve coolant supply tube (Image 1.24.1, Item 1) and




torque the coolant supply tube nut (Image 1.24.1, Item 2) to 18 lb-ft

(24 Nm).

Image1.24.1

Image 1.24.1 EGR Valve Coolant Supply Tube.

1. EGR valve coolant supply tube

2. EGR valve coolant supply tube nut

NOTE: Ensure gasket tab is on inside of mating surface.

6. Remove cap from rear exhaust manifold outlet and install gasket

(Image 1.25.1, Item 1).

Image1.25.1

Image 1.25.1 Rear Exhaust Manifold Outlet Gasket.

1. Rear exhaust manifold outlet gasket

CAUTION: To prevent engine damage, ensure EGR inlet tube gaskets have

the tab at the top so gaskets do not overlap.

7. Install new EGR inlet tube gaskets with tabs pointing up (Image

1.26.1, Item 1).




Image1.26.1

Image 1.26.1 EGR Inlet Tube Gasket.

1. EGR inlet tube gasket

8. Install new EGR inlet tube. Install four heat-resistant bolts (Image

1.27.1, Items 2 and 3) finger tight. Torque bolts to 18 lb-ft (24 Nm).

Image1.27.1

Image 1.27.1 EGR Inlet Tube (Inside).

1. EGR inlet tube (inside)

2. M8 x 25 heat-resistant bolt (2)


9. Install new EGR inlet tube (Image 1.28.1, Item 1). Install four heat-

resistant bolts (Image 128.1, Items 2 and 3) finger tight. Torque bolts

to 18 lb-ft (24 Nm).




Image1.28.1

Image 1.28.1 EGR Inlet Tube (Outside).

1. EGR inlet tube (outside)



10. Install coolant manifold (Image 1.29.1, Item 2), two M8 x 45 bolts

(Image 1.29.1, Item 1), and one M8 x 50 x 16 stud bolt (Image 1.29.1,

Item 3) finger tight. Torque bolts to 26 lb-ft (35 Nm).

CAUTION: To prevent engine damage, extension tubes should be handled

with care.

Image1.29.1


1. M8 x 45 bolt (2)

2. Coolant manifold

3. M8 x 50 x 16 stud bolt

11. Install EGR inlet tube heat shield (Image1.30.1, Item 1), one M8 x

25 heat-resistant bolt (Image 1.30.1, Item 2), and three M8 x 12 bolts

(Image 1.30.1, Item 3) finger tight. Torque bolts to 18 lb-ft (24 Nm).chrismk2




Image1.30.1

Image 1.30.1 EGR Inlet Tube Heat Shield.

1. EGR inlet tube heat shield

2. M8 x 25 heat-resistant bolt

3. M8 x 12 bolt (3)

12. Install HCI coolant outlet tube (Image 1.31.1, Item 1) to HCI,

tighten HCI coolant outlet tube nut (Image 1.31.1, Item 2), and torque

to 11 lb-ft (14.9 Nm).

Image1.31.1

Image 1.31.1 HCI Coolant Outlet Tube.

1. HCI coolant outlet tube

2. HCI coolant outlet tube nut

13. Remove HCI fuel supply line cap (Image 1.32.1, Item 1) and HCI fuel

inlet cap (Image 1.32.1, Item 2).




Image1.32.1

Image 1.32.1 HCI Fuel Supply Line.

1. HCI fuel supply line with cap

2. HCI fuel inlet cap

CAUTION: To prevent component damage, do not bend fuel supply line.

14. Attach HCI fuel supply line nut (Image 1.33.1, Item 1) to HCI fuel

inlet (Image 1.33.1, Item 2) and torque to 18 lb-ft (24 Nm).

Image1.33.1

Image 1.33.1 HCI Fuel Inlet.

1. HCI fuel supply line nut

2. HCI fuel inlet

15. Install Hydrocarbon Injector (HCI) coolant supply tube nut (Image

1.34.1, Item 1) to the coolant manifold (Image 1.34.1, Item 2) and

torque to 18 lb-ft (24 Nm).




Image1.34.1


1. HCI coolant supply tube nut

2. Coolant manifold

16. Connect cab heat tube (Image 1.35.1, Item 1) to coolant manifold

(Image 1.35.1, Item 2).

Image1.35.1

Image 1.35.1 Cab Heat Tube.

1. Cab heat tube

2. Coolant manifold

17. Install cab heater supply tube support brackets (Image 1.36.1, Item

1) to EGR cooler (Image 1.36.1, Item 2) and torque to 13 lb-ft (17.6

Nm).

Image1.36.1 chrismk2Caterpillar: Confidential Yellow



Image 1.36.1 EGR Cooler.

1. Cab heater supply tube bracket

2. EGR cooler

18. Install the engine harness guide (Image 1.37.1, Item 1) to M8 x 45

bolt (Image 1.37.1, Item 2) and torque to 26 lb-ft (35.2 Nm).

Image1.37.1



2. M8 x 45 bolt

3. Engine harness

19. Install the engine harness guide (Image 1.38.1, Item 1) to M8 x 50 x

16 stud bolt (Image 1.38.1, Item 2) and torque to 26 lb-ft (35.2 Nm).

Image1.38.1



2. M8 x 50 x 16 Stud Bolt (not shown, located behind engine harness

guide)

20. Install wire tie (Image 1.39.1, Item 1) located before the EGR valve

electrical connector (Image 1.39.1, Item 2).




Image1.39.1

Image 1.39.1 EGR Valve Electrical Connector.

1. Wire tie

2. EGR valve electrical connector

21. Connect engine harness (Image 1.40.1, Item 1) to EGR valve engine

harness connector (Image 1.40.1, Item 2).

Image1.40.1

Image 1.40.1 EGR Valve Engine Harness Connector.

1. Engine harness

2. EGR valve engine harness connector

22. Connect engine harness (Image 1.41.1, Item 1) to engine coolant

temperature sensor (Image 1.41.1, Item 2).

Image1.41.1




Image 1.41.1 Engine Coolant Temperature Sensor.

1. Engine harness

2. Engine coolant temperature sensor

23. Refill cooling system using the Coolant Management Tool.

24. Install engine cover.

Copyright 1993 - 2013 Caterpillar Inc.

All Rights Reserved.

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Tue Dec 3 13:11:10 CST 2013

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