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General Equipment

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Soap/water solution

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.

    Fig 1: Locating EGR Cooler Assembly Coolant Hoses Clamps
    G07481899Courtesy of FORD MOTOR CO.
  2. Install the EGR Cooler Tester on the low temperature side of the EGR cooler assembly.
    Fig 2: Identifying EGR Cooler Tester On Low Temperature Side Of EGR Cooler Assembly
    G07481900Courtesy of FORD MOTOR CO.
  3. NOTE: 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.

    Fig 3: Locating Connection Of Regulated Air Supply To EGR Assembly Low Temperature Side
    G07481901Courtesy of FORD MOTOR CO.
  4. Observe the pressure gauge, there should be no more than 13.8 kPa (2 psi) drop over a 5 minute period.
  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.
      Fig 5: Locating EGR Cooler Tester Equipment And ECT Sensor
      G07481903Courtesy of FORD MOTOR CO.

    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  and EXHAUST GAS RECIRCULATION (EGR) COOLER - 6.7L DIESEL .

  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).
      Fig 6: Identifying EGR Cooler Tester On High Temperature Side Of EGR Cooler Assembly
      G07481904Courtesy of FORD MOTOR CO.
  9. NOTE: 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.

    Fig 7: Locating Connection Of Regulated Air Supply To High Temperature Side Of EGR Cooler Assembly
    G07481905Courtesy of FORD MOTOR CO.
  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 11.
    • If pressure loss is less than 13.8 kPa (2 psi) go to step  27.
      Fig 8: Locating Pressure Gauge
      G07481906Courtesy of FORD MOTOR CO.
  11. NOTE: 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.

    Fig 9: Locating EGR Cooler Test Equipment
    G07481907Courtesy of FORD MOTOR CO.
  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.
      Fig 10: Identifying EGR Cooler Tester On Low Temperature Side Of EGR Cooler Assembly
      G08598333Courtesy of FORD MOTOR CO.
  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 .
  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.

    Fig 12: Locating Degas Tube
    G07481910Courtesy of FORD MOTOR CO.
  15. Using soap/water solution, test the EGR valve-to-bypass gasket, all the way around the EGR valve.
    Fig 13: Locating EGR Valve-To-Bypass Gasket
    G07481911Courtesy of FORD MOTOR CO.
  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.
    Fig 14: Locating Bypass-To-Cooler Core Gasket
    G07481912Courtesy of FORD MOTOR CO.
  17. Remove the 4 bolts, 2 stud bolts and the EGR cooler end tank.
    Fig 15: Locating EGR Cooler End Tank Bolts And Stud Bolts
    G07481913Courtesy of FORD MOTOR CO.
  18. Using soap/water solution, test around the high temperature O-ring seal.
    Fig 16: Locating High Temperature O-Ring Seal
    G07481914Courtesy of FORD MOTOR CO.
  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.
      Fig 17: Locating EGR Cooler Bolts
      G07481915Courtesy of FORD MOTOR CO.
  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 .
    • If no visible signs of leakage are found go to step  24.
      Fig 18: Locating Sealing Surface Of EGR Valve
      G07481916Courtesy of FORD MOTOR CO.
  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 below:
    • 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.
      Fig 19: Identifying EGR Valve Bolts Tightening Sequence
      G07481917Courtesy of FORD MOTOR CO.
  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 below:
    • Stage 1: Tighten to 15 Nm (133 lb-in).
    • Stage 2: Tighten to 15 Nm (133 lb-in).
      Fig 20: Identifying EGR Cooler End Tank Bolts Tightening Sequence
      G07481918Courtesy of FORD MOTOR CO.
  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.
    Fig 21: Locating EGR Cooler Bolts
    G07481919Courtesy of FORD MOTOR CO.
  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 .
    • If no visible signs of leakage are found go to step 26.
      Fig 22: Locating Cooler Core Sealing Surfaces
      G08598345Courtesy of FORD MOTOR CO.
  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 .
  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.

    Fig 23: Identifying EGR Cooler Tester On Low Temperature Side Of EGR Cooler Assembly
    G07481921Courtesy of FORD MOTOR CO.
  28. NOTE: 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.

    Fig 24: Locating Connection Of Regulated Air Supply With EGR Cooler Low Temperature Side
    G07481922Courtesy of FORD MOTOR CO.
  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.
      Fig 25: Locating Pressure Gauge
      G07481923Courtesy of FORD MOTOR CO.
  30. Using soap/water solution, test the EGR cooler tester equipment.
    Fig 26: Locating EGR Cooler Tester Equipment
    G07481924Courtesy of FORD MOTOR CO.
  31. Using soap/water solution, test around coolant tubes and Engine Coolant Temperature (ECT) sensor, secondary cooling system ECT2.
    Fig 27: Locating Coolant Tubes, ECT Sensor And Secondary Cooling System ECT 2
    G07481925Courtesy of FORD MOTOR CO.
  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.
    Fig 28: Locating Bypass-To-Cooler Core Gasket
    G07481926Courtesy of FORD MOTOR CO.
  33. Remove 4 bolts, 2 stud bolts and the EGR cooler end tank.
    Fig 29: Locating EGR Cooler End Tank Bolts And Stud Bolts
    G07481913Courtesy of FORD MOTOR CO.
  34. Using soap/water solution, test around the low temperature O-ring seal.
    Fig 30: Locating Low Temperature O-Ring Seal
    G07481928Courtesy of FORD MOTOR CO.
  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 .
  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  and EXHAUST GAS RECIRCULATION (EGR) COOLER - 6.7L DIESEL .
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