18SP654* – EPA07 Series 60® Delta Pressure Sensor Removal Kits (P/N: 23538484 and 23538485)

* Revision - 12/17/08 KIT DESCRIPTION New service kits P/N: 23538484 and P/N: 23538485 contain a pipe and associated parts that will replace the venturi and EGR Delta Pressure Sensor. In addition to removing the sensor and related parts, the MCM must be reprogrammed to deactivate the sensor. NOTE: You should not be installing this kit unless there are damaged parts associated with the Delta Pressure Sensor or related parts. KIT CONTENTS The two new service kits contain the parts listed in Table 1:

Part No. Description Horizontal Mixer Kit P/N: 23538484 (qty.)

Vertical Mixer Kit P/N: 23538485 (qty.)

23538615

Tube and flange EGR valve inlet pipe

– horizontal mixer 1 NA

23538616 Tube and flange

EGR valve inlet pipe – vertical mixer

NA 1

23535506 EGR O-ring seals 3 3

23534523 EGR delivery pipe

hose 1 1

23537325 EGR delivery pipe hose clamps 2 2

23538412 Engine harness plug 1 1 05101020 Plastic tie strap 1 1

018SP654 Installation Instructions 1 1

Table 1 EPA07 Series 60 Delta Pressure Sensor Removal Kit Contents

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INSTALLATION PROCEDURE To determine which kit must be used, you will need to determine whether the engine has a horizontal or vertical mixer housing. Refer to Figure 1.

1. Horizontal Mixer Housing 2. Vertical Mixer Housing Figure 1 Horizontal and Vertical Mixer Housings Remove the EGR Delta Pressure Sensor as follows:

PERSONAL INJURY To avoid injury, never remove any engine component while the engine is running.

PERSONAL INJURY To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the starting system.

1. Apply the parking brake, chock the wheels, disconnect vehicle battery power, and perform any other applicable safety steps.

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2. Loosen the two hose clamps that attach the EGR delivery pipe hose to the EGR delivery pipe and venturi. See Figure 2.

1. EGR Delivery Pipe 3. Venturi 2. Hose Clamps 4. EGR Delivery Pipe Hose Figure 2 EGR Delivery Pipe, Hose, Clamps, and EGR Delta Pressure Sensor

Hoses and Clamps

3. Loosen the two clamps that attach the two EGR Delta Pressure Sensor hoses to the venturi, and slide the hoses off the hose barbs on the venturi. See Figure 2.

4. Disconnect the Engine Harness from the EGR valve. Loosen the two hose

clamps on the EGR delivery tube hose. Remove the four bolts securing the EGR valve to the mixer housing. Remove the EGR valve, venturi, EGR delivery pipe hose, and clamps. If equipped with an EGR heater, set aside, being careful not to damage the coolant hoses. Discard the venturi, EGR delivery pipe hose, clamps and two O-ring seals on either side of the EGR valve. See Figure 3.

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1. Venturi 3. EGR Valve 2. EGR Valve Heater Plate 4. Mixer Housing Figure 3 Venturi, EGR Valve Heater Plate (if equipped), and

EGR Valve Removal

5. Disconnect the Engine Harness from the EGR Delta Pressure Sensor. Remove and discard the three bolts and six isolators securing the EGR Delta Pressure Sensor and its plastic mounting bracket. See Figure 4.

1. Engine Harness 4. Plastic EGR Delta Pressure Sensor Bracket 2. EGR Delta Pressure Sensor 5. Steel Mounting Bracket 3. Three Bolts and Six Isolators Figure 4 EGR Delta Pressure Sensor And Mounting Bracket Removal

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6. Install the plug (P/N: 23538412) in the Engine Harness where the EGR Delta Pressure Sensor used to be connected. Use plastic tie strap (P/N: 05101020) to secure the Engine Harness branch that used to go to the EGR Delta Pressure Sensor. Ensure the Engine Harness branch is not loose or near any moving components such as the radiator fan. See Figure 5.

1. Plastic Tie Strap Figure 5 Preferred Location to Tie Strap

7. Install new delivery pipe hose (P/N: 23534523) with two new hose clamps (P/N: 23537325) onto the EGR delivery pipe. Do not tighten the hose clamps.

8. Carefully slide the new tube and flange EGR valve inlet pipe (P/N: 23538413 or

P/N: 23538414) into the new delivery pipe hose. Do not tighten the hose clamps.

9. Position the EGR valve onto the mixer housing with two new O-ring seals (P/N: 23535506). If equipped, position the EGR heater plate assembly with new O-ring seal (P/N: 23535506) between the EGR valve and new tube and flange EGR valve inlet pipe. Using four bolts, attach the tube and flange EGR valve inlet pipe, EGR valve heater plate (if equipped) and EGR valve to mixer housing. Torque four bolts in an X pattern to 30-38 N·m (22-28 lb·ft). Reconnect the Engine Harness to the EGR valve. See Figure 6.

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1. Tube and Flange EGR Valve Inlet Pipe 3. EGR Valve 2. EGR Valve Heater Plate (if equipped) 4. Mixer Housing (Horizontal version shown) Figure 6 Tube and Flange EGR Valve Inlet Pipe, Heater Plate (If equipped),

and EGR Valve Installation

10. If necessary, adjust the location of the delivery pipe hose to ensure a proper fit between the EGR delivery pipe and tube and flange EGR valve inlet pipe. Make sure the pipes are NOT touching inside the hose. If necessary, adjust the pipes to provide clearance.

11. Torque the two EGR delivery pipe hose clamps to 6 – 6.5 N·m (53-57 in·lbs).

ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

12. Reconnect vehicle battery power.

13. Reprogram the MCM to software v61.4.0.0 or higher. Ensure the CPC is programmed to software R03_00_000a or higher. Reference Technical Service letter 08 TS-4.

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ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.

14. Start engine and verify repair.

Specifications are subject to change without notice. Detroit Diesel Corporation is registered to ISO 9001:2001. Copyright © 2008 Detroit Diesel Corporation. All rights reserved. Detroit Diesel Corporation is a Daimler company. 18SP654 Rev. 0812 As technical advances continue, specifications will change. Printed in U.S.A.

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