1. Remove the coolant cap.
2. Examine the EGR cooler for blockages using a boroscope.
If blockages exist: (clean the EGR cooler)
3. Examine the adapter fittings and O-rings of the special tool.
Replace the O-rings in the event of damage, after three test procedures or after one year of proper storage.
4. Clean the contact surfaces of the special tool fittings and EGR cooler exhaust gas inlet and outlet.
5. Add the specified lubricant to the O-rings.
Do not use a silicon-based product.
Silicon-based products can damage the equipment.
6. Install the special tool (A) to the EGR cooler exhaust inlet.
7. Refit the V clamp (10) and tighten it to the specified torque.
8. Insert the plug (E) into the EGR cooler exhaust gas outlet.
9. Install the safety cap (H) over the EGR cooler exhaust gas outlet.
Make sure that the view and leak test port (G) is located on top.
10. Install the half moon flanges (J).
11. Install the safety cap attachment nuts and bolts (F) and hand tighten them.
12. Install the handle (I) and hand tighten it.
13. Close the pressure release valve (B).
14. Close the air flow valve (D).
15. Back off the pressure regulator (C) until it is unloaded.
Failure to back off the pressure regulator (C) can damage the equipment.
16. Supply shop air.
17. Open air flow valve (D).
18. Adjust the pressure regulator (C) to have around 1.40 bar [20 psi] at the pressure gauge of special tool (A).
19. Pressurize the exhaust passages of the EGR cooler for 5 seconds.
If the EGR cooler is over-pressurized:
Close the air flow valve (D).
Open the pressure release valve (B).
Back off the pressure regulator (C).
Restart the procedure from step 13.
20. Close the air flow valve (D).
21. Remove the shop air hose.
22. Check the special tool for pressure decay due to leakage at the flanges.
– If any pressure decay is noticed, look for fitting leakage using soapy water. If necessary, correct the leakage on the fitting.
– Before removing the special tool, depressurize the EGR cooler using the depressurization valve (B) before removing the V clamp (10) or nuts and bolts (F).
– Failure to depressurize the system can cause personal injury.
23. Log the starting pressure.
24. After 15 minutes, examine the results:
– If the pressure does not decay, proceed to the next step.
– If the pressure decays less than 0.14 bar [2 psi], check the integrity of the special tool, then perform the pressure test again.
– If the pressure decays more than 0.14 bar [2 psi], record the pressure and upload the photo to support net, then replace the EGR cooler.
25. Depressurize the special tool using the pressure release valve (B).
Failure to depressurize the system can cause personal injury.
26. Remove the special tool from the vehicle.
27. Install the coolant cap.
