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6.7L EGR Cooler Bench Test

WARNING: This page is about a different car, the 2017 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

The EGR cooler needs to be within 3°C (5°F) of ambient temperature to perform the test. Testing the cooler while hot will give false results.

  1. Remove the EGR cooler and place on a bench for testing. Refer to COOLER, EGR, REMOVAL .
  2. Install a plug into one of the EGR cooler coolant ports.
  3. In the opposite port, install the pressure test adapter.
    NOTE:

    The plug and the adapter must have an air tight fit to prevent misdiagnosis.

  4. Pump up the commercially available pressure tool, while observing the pressure gage. Inspect for air escaping the EGR cooler and pressure test equipment assembly as a result of loose lines and fittings by spraying the exterior of the EGR cooler and all lines and fittings with a mixture of mild soap and water. If there are any air leaks found during the test, fix the leak and start the test over.
    NOTE:

    Do not exceed the pressure indicated on the pressure cap of the cooling system.

  5. Measure and record the air pressure after 20 minutes. If there is no pressure drop, the cooler is reusable.
  6. If the EGR cooler does not remain pressurized, the EGR cooler has an internal leak and must be replaced.
  7. If the EGR cooler holds a steady pressure, then refer to the engine internal leakage inspection. Refer to DIAGNOSIS AND TESTING .
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