C2.2 Engines for Caterpillar Built Machines Caterpillar

Removal Procedure

Start By:

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

2. Disconnect the air induction hose from the turbocharger. Refer to Disassembly and assembly, "Turbocharger - Remove" for the correct procedure.

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Sulfuric Acid Burn Hazard may cause serious personal injury or death. The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.

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Illustration 1	g03815985
Alternator removed for clarity

1. Loosen hose clamp (10) on hose assembly (11). Disconnect hose assembly (11) from exhaust cooler (NRS) (7).

2. Loosen hose clamp (9) on hose assembly (8). Disconnect hose assembly (8) from exhaust cooler NRS) (7).

3. Remove bolts (2) and nuts (6) from tube assembly (1).

4. Remove tube assembly (1) from exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR) valve assembly (3).

5. Remove gasket (4) (not shown) and gasket (5) (not shown).
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   Illustration 2	g03816340
   Typical example

6. Remove bolts (12) from exhaust cooler (NRS) assembly (7).

7. Remove gasket (14) (not shown) from between exhaust manifold (13) and exhaust cooler (NRS) assembly (7).

8. Remove nut (18) from bracket (17). Support exhaust cooler (NRS) assembly (7) as the bolt is removed.

9. Remove exhaust cooler (NRS) assembly (7).

10. If necessary, remove studs (15) from exhaust cooler (NRS) assembly (7).

11. Plug and cap all open ports on exhaust cooler (NRS) assembly (7).

12. If necessary, remove bolt (16) and remove bracket (17).

Installation Procedure

1. Check all components for wear and damage. If necessary, replace any components that are worn or damaged.
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   Illustration 3	g03816340
   Typical example

2. Ensure that the exhaust cooler (NRS) assembly is free from restriction and external damage. Ensure that the exhaust cooler (NRS) assembly and tube assemblies are free from wear and damage. Refer to Systems Operation Testing and Adjusting, "Exhaust Cooler (NRS) - Test" for the correct inspection procedure.

   Note: Cleaning of the internal core of the exhaust cooler (NRS) should not be carried out.

3. Clean the gasket surfaces of exhaust cooler (NRS) assembly (7) and exhaust manifold (13).

4. If necessary, install studs (15) to exhaust cooler (NRS) assembly (7).

5. If necessary, position bracket (17) onto exhaust cooler (NRS) assembly (7). Ensure that the bracket is correctly orientated.

6. Loosely install nut and bolt (18).

7. Remove plug and cap from all open ports of exhaust cooler (NRS) assembly (7)

8. Position exhaust cooler (NRS) assembly (7) onto the cylinder block.

9. Install bolt (16) to bracket (17). Support exhaust cooler (NRS) assembly (7) as bolt (16) is installed.

10. Position a new gasket (14) (not shown) between exhaust manifold (13) and exhaust cooler (NRS) assembly (7).

11. Apply Tooling (A) to the threads of bolts (12). Install bolts (12) to exhaust cooler (NRS) assembly (7) hand tight.

12. Tighten bolts (12) to a torque of 25 N·m (221 lb in).

13. Tighten bolt (16) to a torque of 25 N·m (221 lb in).

14. Tighten locking nut (18) to a torque of 25 N·m (221 lb in). Ensure that bracket (17) is not strained as the nut is tightened.
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    Illustration 4	g03815985
    Typical example

15. Connect hose assembly (11) to exhaust cooler (NRS) (7). Tighten hose clamp (10) securely.

16. Connect hose assembly (8) to exhaust cooler (NRS) (7). Tighten hose clamp (9) securely.

17. Clean the gasket surfaces of tube assembly (1) and exhaust gas recirculation (EGR) valve assembly (3).

18. Apply Tooling (A) to the threads of bolts (2).

19. Position a new gasket (3) (not shown) and a new gasket (5) (not shown) onto tube assembly (1).

20. Position tube assembly (1) onto exhaust cooler (NRS) (7) and exhaust gas recirculation (EGR) valve assembly (3).

21. Apply Tooling (A) to the threads of studs (15).

22. Install bolts (2) and nuts (6) to tube assembly (1). Hand tighten the bolts and nuts.

23. Tighten bolts (2) and nuts (6) to a torque of 25 N·m (221 lb in). Ensure that tube assembly (1) is not strained as the bolts are tightened.

End By:

1. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

2. Connect the air induction hose to the turbocharger. Refer to Disassembly and assembly, "Turbocharger - Install" for the correct procedure.