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Procedures




Exhaust Gas Recirculation (EGR) Cooler Leak Test









On-vehicle EGR cooler leak test

NOTE: Visually inspect for evidence of a coolant leak before performing the on-vehicle test.

NOTE: Only the low temperature side EGR cooler leak test can be done on-vehicle.

1. NOTE: Using hose clamp pliers, clamp the 2 coolant hoses.

Disconnect the 2 coolant hoses from the EGR cooler assembly.





2. Install the EGR Cooler Tester on the low temperature side of the EGR cooler assembly.





3. NOTICE: Do not apply unregulated air supply to the cooler or exceed 414 kPa (60 psi) at any time, excessive pressure can damage the EGR cooler assembly.

Connect a regulated air supply to the low temperature side and slowly adjust the air pressure until 248 kPa (36 psi) is reached, then shut off the air supply.





4. Observe the pressure gauge, there should be no more than 13.8 kPa (2 psi) drop over a 5 minute period.
- If pressure loss is greater than 13.8 kPa (2 psi) go to step 5.

- If pressure loss is less than 13.8 kPa (2 psi) go to Engine Cooling or Powertrain Secondary Cooling Testing and Inspection.





5. Using soap/water solution, test the EGR cooler tester equipment and around coolant tubes and Engine Coolant Temperature (ECT) sensor, secondary cooling system ECT 2.
- If the EGR cooler tester equipment passes and pressure loss is greater than 13.8 kPa (2 psi), remove the EGR cooler and leak test the low temperature side off vehicle. Go to step 6.





Off-vehicle EGR cooler leak test

6. NOTE: Visually inspect for evidence of a coolant leak before performing the off-vehicle test.

Remove the EGR cooler assembly. For additional information, refer to Exhaust Gas Recirculation (EGR) Cooler - Exploded View, 6.7L Diesel Exhaust Gas Recirculation (EGR) Cooler - Exploded View and Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Exhaust Gas Recirculation (EGR) Cooler.

7. For high temperature side EGR cooler test, go to step 8, for low temperature side EGR cooler test, go to step 27.

8. Install the EGR Cooler Tester on the high temperature side of the EGR cooler assembly.
- Tighten the 3 bolts to 10 Nm (89 lb-in).





9. NOTICE: Do not apply unregulated air supply to the cooler or exceed 414 kPa (60 psi) at any time, excessive pressure can damage the EGR cooler assembly.

Connect a regulated air supply to the high temperature side and slowly adjust the air pressure until 248 kPa (36 psi) is reached, then shut off the air supply.





10. Observe the pressure gauge, there should be no more than 13.8 kPa (2 psi) drop over a 5 minute period.
- If pressure loss is greater than 13.8 kPa (2 psi) go to step 10.

- If pressure loss is less than 13.8 kPa (2 psi) go to step 27.





11. NOTICE: Do not submerge the EGR cooler assembly in water or damage to EGR valve will occur.

Using soap/water solution, test around the EGR cooler test equipment.





12. Install the EGR cooler tester on the low temperature side of the EGR cooler assembly, then shut off the air supply valve on the low temperature side. Slowly adjust the air pressure on the high temperature side until 248 kPa (36 psi) is reached, leaving the air supply valve open.
- Observe the low temperature side pressure gauge for 15 minutes, if low pressure gauge increases by 13.8 kPa (2 psi), go to step 13.

- If no pressure rise on the low temperature side gauge, remove the low temperature side test equipment and go to step 14.





13. Disassembly the EGR cooled assembly and inspect the cooler side gasket for coolant staining in the gas passages. If visible signs of leaks are present, inspect sealing surfaces for imperfections. For additional information, refer to the disassembly and assembly of the Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Overhaul.
- If the sealing surface is unacceptable, replace the necessary parts. For additional information, refer to the disassembly and assembly of the Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Overhaul.

- If no staining is found, replace the cooler housing and all the gaskets and O-ring seals. For additional information, refer to the disassembly and assembly of the Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Overhaul.





14. NOTE: Ensure the air pressure is still 248 kPa (36 psi), leaving the air supply valve open.

Using soap/water solution, test around the degas tube.





15. Using soap/water solution, test the EGR valve-to-bypass gasket, all the way around the EGR valve.





16. Using soap/water solution, test the gasket joints on both sides of the bypass-to-cooler core gasket, all the way around the bypass.





17. Remove the 4 bolts, 2 stud bolts and the EGR cooler end tank.





18. Using soap/water solution, test around the high temperature O-ring seal.





19. If the cooler is still losing pressure and no bubbles have been found in steps 14 through 18, remove the 13 bolts and the EGR valve from the bypass, keeping the bypass on the cooler.
- Discard the gasket and the 13 bolts.





20. Inspect for coolant staining in the gas passages of the EGR valve and bypass. If visible signs of leaks are present, inspect sealing surfaces for imperfections.
- If the sealing surface is acceptable, reinstall the EGR valve with a new gasket and bolts and retest. Go to steps 19 through 21.

- If the sealing surface is unacceptable, replace the necessary parts. For additional information, refer to the disassembly and assembly of the Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Overhaul.

- If no visible signs of leakage are found go to step 24.





21. Using a new EGR valve gasket and the 13 new bolts, install the EGR valve and the bolts and tighten in 4 stages in the sequence shown:
- Stage 1: Tighten bolts 1 through 12 to 12 Nm (106 lb-in).

- Stage 2: Tighten bolts 1 through 12 to 16 Nm (142 lb-in).

- Stage 3: Tighten bolts 1 through 4 to 16 Nm (142 lb-in).

- Stage 4: Tighten bolt 13 to 12 Nm (106 lb-in), then an additional 90 degrees.





22. Using a new EGR cooler end tank gasket, install the EGR cooler end tank, 4 bolts and 2 stud bolts and tighten in 2 stages in the sequence shown:
- Stage 1: Tighten to 15 Nm (133 lb-in).

- Stage 2: Tighten to 15 Nm (133 lb-in).





23. Adjust the air pressure until 248 kPa (36 psi) is reached, using soap/water solution, test the EGR valve-to-bypass gasket, all the way around the EGR valve.
- If the EGR cooler assembly passes, return to service.

- If the EGR cooler assembly fails, go to step 24.

24. If no visible signs of leakage are found, remove the 9 bolts and the bypass from the cooler.





25. Inspect for coolant staining in the bypass and cooler core. Inspect sealing surfaces for imperfections, porosity or scratches.
- If visible signs of leakage are present replace all gaskets, O-ring seals and bypass as necessary. For additional information, refer to the disassembly and assembly of the Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Overhaul.

- If no visible signs of leakage are found go to step 26.





26. If no staining is found replace the EGR cooler core and all gaskets and O-rings seals. For additional information, refer to the disassembly and assembly of the Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Overhaul.

27. NOTE: Remove the EGR Cooler Tester from the high temperature side of the EGR cooler.

Install the EGR Cooler Tester on the low temperature side of the EGR cooler assembly.





28. NOTICE: Do not exceed 414 kPa (60 psi) at any time, excessive pressure can damage the EGR cooler assembly.

Connect a regulated air supply to the low temperature side and slowly adjust the air pressure until 248 kPa (36 psi) is reached, then shut off the air supply.





29. Observe the pressure gauge, there should be no more than 13.8 kPa (2 psi) drop over a 5 minute period.
- If pressure loss is greater than 13.8 kPa (2 psi) go to step 30.

- If pressure loss is less than 13.8 kPa (2 psi) go to step 36.





30. Using soap/water solution, test the EGR cooler tester equipment.





31. Using soap/water solution, test around coolant tubes and Engine Coolant Temperature (ECT) sensor, secondary cooling system ECT2.





32. Using soap/water solution, test the gasket joints on both sides of the bypass-to-cooler core gasket, all the way around the bypass.





33. Remove 4 bolts, 2 stud bolts and the EGR cooler end tank.





34. Using soap/water solution, test around the low temperature O-ring seal.





35. If no external leaks are found but leak test still fails, replace EGR cooler core, all gaskets and O-ring seals. For additional information, refer to the disassembly and assembly of the Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Overhaul.

36. If no leaks are detected from both the high temperature and low temperature test, return the EGR cooler assembly to service. Install the EGR cooler assembly. For additional information, refer to Exhaust Gas Recirculation (EGR) Cooler - Exploded View, 6.7L Diesel Exhaust Gas Recirculation (EGR) Cooler - Exploded View and Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel Exhaust Gas Recirculation (EGR) Cooler.

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