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5 17-13
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5 17-13
SUBJECT
DATE
EGR Actuator
May 2013
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
Change
Description and
Operation of the DD13
Exhaust Gas
Recirculation Valve
Actuator
Removal of the DD13
Exhaust Gas
Recirculation Valve
Actuator
Installation of the DD13
Exhaust Gas
Recirculation Valve
Actuator
DDC-SVC-MAN-0083
DD Platform
Added Sonceboz actuator.
Description and
Operation of the DD15
and DD16 Exhaust Gas
Recirculation Valve
Actuator
Removal of the DD15
and DD16 Sonceboz
Exhaust Gas
Recirculation Valve
Actuator
Installation of the DD15
and DD16 Sonceboz
Exhaust Gas
Recirculation Valve
Actuator
All information subject to change without notice.
5 17-13 Copyright © 2013 DETROIT DIESEL CORPORATION
This is a new section.
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All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 17-13
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Description and Operation of the DD13 Exhaust Gas Recirculation
Valve Actuator
The Exhaust Gas Recirculation (EGR) system is controlled by the Motor Control Module (MCM) via a CAN signal which
controls the EGR valve actuator. The EGR valve actuator then opens and closes the EGR valve to achieve the desired flow
through the EGR cooler where the high temperature gas is cooled and then directed through the mixing pipe where it is
mixed with air from the Charge Air Cooler (CAC) and directed into the cylinders.
When production of the DD13 began, a Delphi® actuator was utilized. Beginning with engine serial number HDE108907,
the Sonceboz® actuator was introduced. Both actuators work the same, but are not interchangeable.
1.
2.
3.
4.
5.
6.
7.
8.
Bolt
Exhaust Gas Recirculation Valve Actuator
Spacer
Spacer
Lever
Bolt
Clamping Nut
Actuator Pull Rod (EPA07 Version)
9.
10.
11.
12.
13.
14.
15.
16.
Clamping Nut
Fitting
Seal Ring
Coolant Inlet Line
Coolant Outlet Line
Banjo Bolt
Harness Plug
Actuator Pull Rod (EPA10 Version)
Figure 1. DD13 Exhaust Gas Recirculation Valve Actuator and Related Parts
All information subject to change without notice.
5 17-13 Copyright © 2013 DETROIT DIESEL CORPORATION
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2 Description and Operation of the DD13 Exhaust Gas Recirculation Valve Actuator
1.
2.
3.
4.
5.
6.
7.
8.
Exhaust Gas Recirculation Valve Actuator
Bolts
Stud
Lever
Nut
Actuator Pull Rod
Nut
Seal Rings
9.
10.
11.
12.
13.
14.
15.
Banjo Bolt
Coolant Inlet Line
Stud
Exhaust Gas RecirculationValve Lever
Coolant Outlet Line
Coolant Fittings
Harness Plug
Figure 2. DD13 Sonceboz® Exhaust Gas Recirculation Valve Actuator and Related Parts
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All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 17-13
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Removal of the DD13 Exhaust Gas Recirculation Valve Actuator
Remove as follows:
NOTE: The clamping bolt and actuator rod must remain installed to the actuator linkage when removing or
installing the lock nut to avoid damage to the actuator valve gears.
1. Drain the coolant. Refer to section "Cooling System Drain Procedure".
2. Remove one nut connecting the Exhaust Gas Recirculation (EGR) valve actuator to the linkage and remove linkage
from the actuator.
NOTICE: To prevent damage to the coolant inlet and outlet lines, hold the coolant line fittings with a wrench
during line removal.
3.
4.
5.
6.
Remove the coolant line from the EGR valve actuator and cylinder block.
Remove the coolant line from the EGR valve actuator and water manifold.
Disconnect the EGR valve actuator electrical harness connector from the engine electrical harness.
Remove the EGR valve actuator from the cylinder block.
a. For the Delphi actuator, remove three bolts and spacers from EGR valve actuator and remove actuator from the
cylinder block.
b. For the Sonceboz actuator, remove the three bolts from the EGR valve actuator and remove actuator from the
cylinder block.
All information subject to change without notice.
5 17-13 Copyright © 2013 DETROIT DIESEL CORPORATION
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4 Installation of the DD13 Exhaust Gas Recirculation Valve Actuator
4
Installation of the DD13 Exhaust Gas Recirculation Valve Actuator
Install as follows:
NOTICE: If reusing the original Exhaust Gas Recirculation (EGR) valve actuator bracket bolts, always apply a
small amount of copper-based anti-seize compound to the bolts. The original coating will burn off and that makes
it necessary to reapply the anti-seize compound.
NOTICE: Ensure the bracket and exhaust manifold are at ambient temperature when the actuator bracket bolts
are torqued.
NOTICE: Do not turn on the ignition power until all of the installation steps are completed.
1. Install the EGR valve actuator to cylinder block.
a. For the Delphi actuator, install the EGR valve actuator to cylinder block with the bolts and two spacers. Torque
bolts to 30 N•m (22 lb•ft).
b. For the Sonceboz actuator, install the EGR valve actuator to cylinder block with the bolts. Torque bolts to 30
N•m (22 lb•ft).
2. Install the EGR valve actuator rod onto the actuator. Apply a small amount of copper based anti-seize compound to the
nut threads and tighten. Torque nut to 20 N•m (15 lb•ft).
NOTICE: To prevent damage to the coolant inlet and outlet lines, hold the coolant line fittings with a wrench
during line installation.
3. Install the coolant line to the EGR valve actuator and fitting on cylinder block. Tighten coolant line to EGR valve
actuator to 25 N•m (18 lb•ft). Tighten coolant line to fitting on cylinder block 40 N•m (29 lb•ft).
4. Install the coolant line to the EGR valve actuator and water manifold. Tighten coolant line to 35 N·m (26 lb·ft).
5. Connect the EGR valve actuator to the engine wiring harness.
6. Fill the coolant system. Refer to section "Cooling System Fill Procedure".
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All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 17-13
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Description and Operation of the DD15 and DD16 Exhaust Gas
Recirculation Valve Actuator
The Exhaust Gas Recirculation (EGR) system is controlled by the Motor Control Module (MCM) via a CAN signal which
controls the EGR valve actuator. The EGR valve actuator then opens and closes the EGR valve to achieve the desired flow
through the EGR cooler where the high temperature gas is cooled and then directed through the mixing pipe where it is
mixed with air from the Charge Air Cooler (CAC) and then directed to the cylinders.
When production of the DD15 and DD16 began, a Delphi® actuator was utilized. Beginning with engine serial number
HDE172591 the Sonceboz® actuator was introduced. Both actuators work the same, but are not interchangeable.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Banjo Bolt
Adaptor Fitting
Seal Ring
Coolant Outlet Line
Coolant Inlet Line
Exhaust Gas Recirculation Valve Actuator
Lock Nut
Clamping Nut
Exhaust Gas Recirculation Valve Actuator Pull Rod
Bolt
11.
12.
13.
14.
15.
16.
17.
18.
19.
Washer
Exhaust Gas Recirculation Valve
Stud
Stud Nut
Bolt
Thermal Washer
Bracket
Gasket
Electrical Harness Connector
Figure 3. DD15 and DD16 Delphi® Exhaust Gas Recirculation Valve Actuator
All information subject to change without notice.
5 17-13 Copyright © 2013 DETROIT DIESEL CORPORATION
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5 Description and Operation of the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator
1.
2.
3.
4.
5.
6.
7.
Nut
Stud
Actuator Pull Rod
Actuator Lever
Stud
Exhaust Gas Recirculation Valve Actuator
Bolt
8.
9.
10.
11.
12.
13.
Retaining Clip
Sealing Washer
Coolant Line Fitting
Outlet Coolant Line
Inlet Coolant Line
Harness Plug
Figure 4. DD15 and DD16 Sonceboz® Exhaust Gas Recirculation Valve Actuator and Related Parts
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All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 17-13
5 17-13
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Removal of the DD15 and DD16 Sonceboz® Exhaust Gas Recirculation
Valve Actuator
Remove as follows:
NOTICE: The clamping nut and actuator rod must remain installed to the actuator linkage when removing or
installing the lock nut to avoid damage to the actuator valve gears.
1. Drain the coolant. Refer to section "Cooling System Drain Procedure".
2. Remove Exhaust Gas Recirculation (EGR) valve pull rod from the EGR actuator lever.
NOTICE: To prevent damage to the coolant inlet and outlet lines, hold the coolant line fittings with a wrench
during line removal.
3. Remove the coolant outlet line from the EGR actuator adaptor fitting and water manifold adaptor fitting.
4. Remove the coolant inlet line from the EGR actuator and cylinder block adaptor fitting.
5. Disconnect the EGR Valve actuator electrical harness connector (3) from the engine electrical harness.
6. Unclip the EGR actuator electrical harness (3) from the clip behind the turbocharger.
7. Unclip the EGR actuator electrical harness (2) from the attachment point (1) below the actuator.
All information subject to change without notice.
5 17-13 Copyright © 2013 DETROIT DIESEL CORPORATION
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6 Removal of the DD15 and DD16 Sonceboz® Exhaust Gas Recirculation Valve Actuator
NOTICE: To prevent damage to the coolant inlet and outlet lines, hold the adaptor fittings with a wrench during
line removal.
NOTE: DO NOT drop washers from the bottom of the brackets.
8. Remove the three bolts and washers from actuator and remove actuator from bracket.
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All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 17-13
5 17-13
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Installation of the DD15 and DD16 Sonceboz® Exhaust Gas
Recirculation Valve Actuator
Install as follows:
1. Install the Exhaust Gas Recirculation (EGR) actuator onto the mounting bracket with three bolts and washers. Torque
bolts to 25 N•m (18 lb•ft).
2. Install the pull rod onto actuator and secure with one nut. Tighten nut to 25 N• m (18 lb• ft).
3. Position the EGR actuator electrical harness behind the turbo and connect it to the mounting point on the block (3).
4. Connect the EGR actuator electrical harness to the engine electrical harness.
5. Clip the EGR actuator electrical harness to the attachment point behind the turbo (2).
6. Clip the EGR actuator electrical harness (2) to the attachment point (1) below the EGR actuator.
All information subject to change without notice.
5 17-13 Copyright © 2013 DETROIT DIESEL CORPORATION
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7 Installation of the DD15 and DD16 Sonceboz® Exhaust Gas Recirculation Valve Actuator
7. If removed, install the coolant line fittings on the inlet and outlet coolant ports of the EGR actuator. Torque fittings to
25 N•m (18 lb•ft).
NOTICE: To prevent damage to the coolant inlet and outlet lines, hold the coolant line fittings with a wrench
during line installation.
8. Install the coolant inlet line from the EGR actuator fitting to the cylinder block adaptor fitting. Torque fittings to 30
N•m (22 lb•ft).
9. Install the coolant outlet line from the EGR actuator fitting to the cylinder block adaptor fitting. Torque fittings to 30
N•m (22 lb•ft).
10. Fill the cooling system with coolant. Refer to section "Cooling System Fill Procedure".
WARNING: 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.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
11. Start the engine and allow the actuator to cycle completely. This will allow the system to learn the stops of the EGR
valve.
12. Check for leaks.
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All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 17-13
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