Sb-15-010 11my-15my Egr Valve Heater

Group: 0-General
Bulletin No.: SB-15-010

Issue Date: 01-20-2014
TECHNICAL SERVICE BULLETIN

2011MY-15MY EGR (Exhaust Gas Recirculation) Valve Heater
OVERVIEW
Some vehicles that operate in extreme cold weather climates may exhibit ice accumulation on the EGR
(Exhaust Gas Recirculation) butterfly plate with a repeat P1604 DTC (Diagnostic Trouble Code) stored in the
engine ECU. A heated EGR valve has been made available to prevent this occurrence.
NOTE: Please note that this bulletin is to be used in conjunction with the cold weather enhancement
procedure (A-15-012).
NOTE: This procedure is provided as technical information and is not an authorization for a warranty repair.
SUBJECT VEHICLES
2011MY – 2015MY Hino Conventional NE8J, NJ8J and NV8J trucks built before 10/15/14
BEFORE YOU BEGIN:

- Read and understand all instructions and procedures before you begin the work.
- Read and follow all WARNINGS and NOTICES set forth in this publication. These alerts help to avoid damage
to components, serious personal injury, or both.
- Park the vehicle on a flat, level and solid surface.
- Place the gear shift lever in "Neutral" or "Park".
- Apply the parking brake firmly and confirm parking brake activation.
- Turn off the engine and remove the key from the ignition switch.
- Always wear safety glasses or goggles to protect your eyes.
Place wheel chocks in front of and behind all the wheels to prevent the vehicle from moving.
PARTS:
PART NUMBER DESCRIPTION QUANTITY
EGRKIT11-13MY EGR PIPE KIT(2011-2013MY) As Needed
EGRKIT14-15MY EGR PIPE KIT(2014-2015MY) As Needed
KIT CONTENTS:
KIT PART NUMBER: EGRKIT11-13MY EGR PIPE KIT(2011-2013MY)
SH552-11025 BOLT, FLANGE 3
SH552-11075 BOLT, FLANGE 4
SZ209-16014 WASHER, SOFT 2
SZ401-16012 BOLT 2
25601-E0510 PIPE SUB-ASSY, EGR 1
Page 1 of 10 Vendor Ref.: HMM-150115-B1

Group: 0-General

SL722-01010 WASHER 1
25627-E0070 GASKET, EGR VALVE 2
25634-E0020 GASKET, EGR PIPE 1
SH552-10835 BOLT,FLANGE 2
SZ401-16012 BOLT 2
S2942-E0431 PIPE, AIR COMPR COOLANT, OUTLET 1
S7990-42180 CLIP SUB ASSY 4
KIT PART NUMBER: EGRKIT14-15MY EGR PIPE KIT(2014-2015MY)

SZ401-16012 BOLT 2
25601-E0561 PIPE SUB-ASSY, EGR 1
25627-E0070 GASKET, EGR VALVE 2
25634-E0020 GASKET, EGR PIPE 1
SZ401-16012 BOLT 2
S7990-42180 CLIP SUB ASSY 4
VEHICLE PREPARATION:
1. Park the vehicle on a flat level and solid

surface.

Group: 0-General

2. Confirm the engine is stopped, the
ignition switch in the off (LOCK) position
and the key is removed.
3. Apply the parking brake.
4. Chock all of the wheels.

Group: 0-General

INSTALLATION PROCEDURE
WARNING: The vehicle must be completely cooled before starting this procedure. Failure to allow the vehicle
to cool completely may result in serious burn injuries.
1. Drain the coolant from the engine into an

appropriate container by loosening the drain
plug on the oil cooler on the passenger side of
the engine block. Once the coolant has
drained, tighten the drain plug to the specified
torque.
Specified Torque: 32.5 lb-ft (44 Nm)
2. Remove the EGR cooler outlet temperature sensor. For 2011-2013MY, slide the connector
off the mounting tab before removing the sensor so the wires can rotate. For 2014-2015MY the
sensor uses a rotating threaded collar around the sensor, and does not have to be
disconnected. Remove the EGR outlet temperature sensor from the EGR pipe, as shown near
the bottom of both photographs below. Retain all parts for reassembly.
2011-2013MY 2014-2015MY

Group: 0-General
3. Remove the seven mounting bolts from

the EGR pipe. Remove the EGR pipe and
gaskets. Discard the bolts, pipe, and gaskets.
4. In order to remove the gasket from under the EGR valve and clean the mating surface of the
EGR valve and intake manifold, it will be necessary to remove the nut securing the EGR valve to
the brace attached to the side of the actuator. Retain this nut for reassembly and discard the
EGR valve gasket. Refer to the photographs below for reference.

Group: 0-General

5. Remove the two bolts securing the pipe clips that hold the air compressor coolant pipe to
the intake manifold. Remove the union bolts and sealing washers from the air compressor head
and engine block. Discard these components. Refer to the photographs below for reference.
6. To remove the air compressor coolant pipe, two harness retainers at the front and center of
the intake manifold will need to be removed to allow clearance. Remove one bolt per harness
retainer and then remove the air compressor coolant pipe. Refer to the photographs below for
reference. Once the coolant pipe is removed, the harness retainers can be reinstalled and the
bolts tightened to the specified torque. Discard the coolant pipe.
Specified Torque: 21 lb-ft (28.5 Nm)

Group: 0-General
7. Clean the mating surface between the EGR

valve and the intake manifold and place a new
gasket in between these components
New Gasket
8. Thread the EGR valve brace nut back on the

stud on the EGR valve, but do not tighten at
this time.
9. Install the new EGR pipe along with two new gaskets and seven new bolts. Hand tighten all
bolts prior to tightening to the specified torque. Once the EGR pipe bolts have been tightened
to the specified torque, tighten the EGR valve brace nut to the specified torque.
EGR Pipe Bolts: 40.5 lb-ft (55 Nm)

EGR Valve Brace Nut: 21 lb-ft (28.5 Nm)

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10. Install the two new air compressor coolant pipes using the four new union bolts and four
new sealing washers to route coolant through the new EGR pipe. Hand tighten all union bolts
and then tighten to the specified torque. Refer to the highlighted portions of the photographs
below for pipe routing.
Specified Torque: 22 lb-ft (29.4 Nm)
11. Install the two new coolant pipe

attachment clips and bolts. These install in the
same locations on the intake manifold from
which the old components were removed.
Tighten the bolts to the specified torque.
Specified Torque: 2.5 lb-ft (3.4 Nm)

Group: 0-General

12. Clean the threads on the EGR cooler outlet temperature sensor that was removed in step 2.
Reinstall the sensor and torque to the specified torque. Reconnect the electrical connector and
harness clip for 2011-2013MY vehicles.
EGR Temperature Sensor 2011-2013MY: 14.5 lb-ft (19.6 Nm)

EGR Temperature Sensor 2014-2015MY: 22 lb-ft (30 Nm)
2011-2013MY 2014-2015MY
13. Refill the cooling system using the coolant

that was drained from the vehicle.
14. Run the engine to purge the air from the cooling system. Verify that there are no leaks from
the cooling system or the EGR pipe.

Group: 0-General

FINAL INSPECTION PROCEDURE
1. To complete this Technical Service Bulletin, review the bulletin and confirm the following:
 All fasteners have been torqued properly.
 The EGR pipe and coolant lines have been checked for leaks.
 The cooling system has been purged of any air and filled to proper level.
NOTE: This procedure is provided as technical information and is not an authorization for a warranty repair.
CLAIM APPLICATION
* Reimbursable in accordance within the terms and policies of the Hino Truck limited warranties.
a) Labor Charge: 1.4 Hours
b) Warranty Code: 05220
c) Trouble Code: 40
d) Operation Code: 05250AOT
e) Part Number: 9999999999

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Group: 0-General

Bulletin No.: SB-15-010

TECHNICAL SERVICE BULLETIN

BEFORE YOU BEGIN:

Page 1 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

KIT PART NUMBER: EGRKIT14-15MY EGR PIPE KIT(2014-2015MY)

1. Park the vehicle on a flat level and solid

Page 2 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

3. Apply the parking brake.

4. Chock all of the wheels.

Page 3 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

1. Drain the coolant from the engine into an

Specified Torque: 32.5 lb-ft (44 Nm)

Page 4 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

3. Remove the seven mounting bolts from

Page 5 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

Specified Torque: 21 lb-ft (28.5 Nm)

Page 6 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

7. Clean the mating surface between the EGR

8. Thread the EGR valve brace nut back on the

EGR Pipe Bolts: 40.5 lb-ft (55 Nm)

Page 7 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

Specified Torque: 22 lb-ft (29.4 Nm)

11. Install the two new coolant pipe

Specified Torque: 2.5 lb-ft (3.4 Nm)

Page 8 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

EGR Temperature Sensor 2011-2013MY: 14.5 lb-ft (19.6 Nm)

13. Refill the cooling system using the coolant

Page 9 of 10 Vendor Ref.: HMM-150115-B1

TECHNICAL SERVICE BULLETIN

Page 10 of 10 Vendor Ref.: HMM-150115-B1

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