Overhaul

Exhaust Gas Recirculation (EGR) Cooler - 6.7L Diesel













Disassembly

NOTICE: If the bypass is replaced, all gaskets and seals must be replaced or damage to the EGR cooler may occur.

NOTICE: Caution must be observed when removing the EGR cooler core as to avoid sealing flange scratches or damage to the sealing surfaces may occur.

NOTICE: Do not attempt to remove the cooler core by prying between the header plate and housing or damage to the cooler core will occur.

NOTE: The bypass must be replaced with the EGR cooler assembly off the engine.

1. Disconnect the bypass valve solenoid-to-bypass actuator vacuum hose.

2. Remove the 2 bolts and the bypass valve solenoid.

3. Remove the 2 screws and the bypass actuator.

4. Remove the 4 bolts, 2 stud bolts and the EGR cooler end tank.
- Discard the EGR cooler end tank gasket.





5. Remove the 13 bolts and the EGR valve.
- Discard the 13 bolts and EGR valve gasket.





6. Remove the 9 bolts and the bypass.
- Discard the 9 bolts and bypass gasket.





7. Using 2 equal length of wood, insert them into the opening at the EGR cooler end tank until they touch the EGR cooler core.





8. NOTE: A snug fit of the wood will keep the wood from falling out of the EGR cooler and will aid in the removal of the EGR cooler.

NOTE: The EGR cooler O-ring seals are very robust and will hold the cooler core very tight in the EGR cooler housing.

Holding the EGR cooler housing, strike the EGR cooler housing down on the wood forcing the EGR cooler core out of the housing.

- Discard the EGR cooler core gasket.





9. Remove the 4 EGR cooler core insulators.





10. Remove and discard the 2 EGR cooler O-ring seals and clean O-ring seal seat on the EGR cooler housing.





11. NOTE: Gaskets are sensitive to debris and surface defects, sealing surfaces must be thoroughly cleaned before new gaskets are installed.

NOTE: Scratches as shown may lead to leaks.

Inspect all cooler sealing surfaces for defects that may lead to a leak path. If defects are found, replace the components as required.





Assembly

1. Using 2 new O-ring seals, install the O-ring seals in the EGR cooler housing and lube the O-ring seals with clean engine coolant to ease installation.





2. NOTICE: Inspect the new EGR cooler core gasket for correct location, it is marked COOLER SIDE on the upper left hand corner. Incorrect installation of this gasket could result in an internal coolant leak to the exhaust and severe engine damage.

Using a new EGR cooler core gasket, marked "cooler side", install the EGR cooler gasket on the cooler core as shown.





3. Install the 4 EGR cooler core insulators.





4. NOTICE: Handle the EGR cooler core and housing assembly carefully as the EGR cooler core could slide out of the housing and damage to the EGR cooler core may occur.

Install the EGR cooler core into the EGR cooler housing, using even pressure to seat on the O-ring seals.





5. NOTICE: Inspect the new bypass gasket for correct location, it is marked BYPASS SIDE on the upper right hand corner. Incorrect installation of this gasket could result in an internal coolant leak to the exhaust and severe engine damage.

Install the bypass gasket as shown.

- If replacing the EGR valve and bypass as an assembly, go to step 5. If replacing the bypass only, go to step 6.





6. Using 9 new bolts and 1 new EGR valve long center bolt, install the EGR valve and bypass assembly and the 10 bolts and tighten in the sequence shown in 3 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 12 Nm (106 lb-in).

- Stage 3: Tighten to 12 Nm (106 lb-in) and then an additional 90 degrees.

- Go to step 6.





7. Using 9 new bolts, install the bypass and the 9 bolts and tighten in the sequence shown in 3 stages:
- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten to 12 Nm (106 lb-in).

- Stage 3: Tighten to 12 Nm (106 lb-in) and then an additional 90 degrees.





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

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

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

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





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

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





10. Install the bypass actuator and the 2 screws.

11. Install the bypass valve solenoid and the 2 bolts.

12. Connect the bypass valve solenoid-to-bypass actuator vacuum hose.

13. NOTE: Ensure all EGR cooler assembly gaskets, O-rings and fasteners have been replaced.

The EGR cooler assembly must be leak tested after assembly. For additional information, refer to Exhaust Gas Recirculation (EGR) Cooler Leak Test Procedures.