Exhaust Gas Recirculation (EGR) Cooler Leak Test

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

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Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	303-1511 Tester, EGR Cooler Pressure

Leak detection

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

Remove the Exhaust Gas Recirculation (EGR) Cooler.
Install the EGR Cooler Pressure Tester on the EGR cooler. Tighten the bolts. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.
Torque: 89 lb.in (10 Nm)

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NOTE: Do not apply an unregulated air supply to the EGR cooler or exceed 248 kPa (36 psi) at any time, excessive pressure can damage the EGR cooler assembly.
1. Adjust the EGR Cooler Pressure Tester air pressure regulator to the lowest setting.
2. Close the EGR Cooler Pressure Tester air supply shutoff valve.
3. Connect the regulated air supply to the EGR Cooler Pressure Tester.
4. Open the EGR Cooler Pressure Tester air supply shutoff valve.
5. Slowly adjust the EGR Cooler Pressure Tester air pressure regulator until 248 kPa (36 psi) is reached.
6. Close the EGR Cooler Pressure Tester air supply shutoff valve. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.
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- Observe the EGR Cooler 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 step 6. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.
Courtesy of FORD MOTOR COMPANY
NOTE: Do not submerge the EGR cooler assembly in water or damage to EGR valve will occur.

Using a soap/water solution, test around the EGR Cooler test equipment. Repair as needed. Use Special Service Tool: 303-1511 Tester, EGR Cooler Pressure.

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If pressure decay greater than 2 psig in 180 seconds is observed, spray soapy water to sealed joints between EGR valve, EGR cooler bypass and EGR cooler shell to identify source of leak. Using a soap/water solution, test the EGR valve-to-bypass gasket, all the way around the EGR valve.

Courtesy of FORD MOTOR COMPANY
If pressure decay greater than 2 psig in 180 seconds is observed, spray soapy water to sealed joints between EGR valve, EGR cooler bypass and EGR cooler shell to identify source of leak. Using a soap/water solution, test the gasket joints on both sides of the bypass-to-cooler core gasket, all the way around the bypass.

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If no staining is found, then go to step 9.
If no external leaks are found but leak test still fails, replace EGR cooler.
If no leaks are detected from the test, then return the EGR cooler assembly to service.