Question 1

How to Service the EGR Cooler on Ford F-250 Super Duty?

Accepted Answer

The service of the Exhaust Gas Recirculation (EGR) cooler requires technicians to first remove the degas bottle assembly and subsequent detachment of the upper radiator hose quick connect coupling by syrming the spring clip. Start by removing two mounting bolts to move the power steering reservoir away from its position. The fuel cooler tube requires being detached from its power steering reservoir retainer before the procedure. You should disconnect the clamp holding the CAC tube flex joint to the turbocharger before placing the CAC tube to the side. The maintenance only proceeds with removal of both cooling fan stator units along with separation of the exhaust gas recirculation temperature sensor outlet connector. Detach the EGR valve coolant supply hose from both its retainer point on the EGR cooler and its position on the EGR cooler. After that remove the EGR cooler coolant hose position retainer nut then the retainer itself. Disassembling the EGR cooler begins with extracting its upper nut and bolt and upper stud before releasing the lower two nuts and two studs and the discardable inlet gasket. Begin by removing the three nuts because they separate the EGR cooler support clamps while marking their locations on the bracket first. Deactivate the EGR cooler by disconnecting its coolant inlet hose and throwing out the clamp before putting the cooler in place to disconnect its outlet hose along with its discarded clamp. Discard both the outlet gasket while removing the EGR cooler component. The procedure starts by taking out the power steering tube position retainers nut followed by placing the power steering tubes aside then removing the two EGR cooler support bracket lower bolts together with the stud bolt before ending in upper bolt removal of the EGR cooler support bracket. These components require discarding the three support clamps. Place new EGR cooler support clamps onto the EGR cooler bracket before installing the bracket using its bolts and stud bolt with only finger pressure to maintain clamp looseness. Fasten the EGR cooler outlet hose to its nozzle using a fresh clamp while keeping EGR cooler clamp nuts gently tightened. Apply a new clamp to connect the EGR cooler coolant inlet hose before tightening both inlet and outlet hose clamps to 4 Nm (35 lb-in). Install a new EGR cooler outlet gasket before putting it into position then tighten the upper stud to 31 Nm (23 lb-ft) followed by slowly tightening the upper bolt and nut. Mount the inlet gasket followed by the lower gasket and tighten the two lower studs to 17 Nm (13 lb-ft). Afterward, fasten the lower retaining nuts by hand only. Position the EGR cooler clamps where marked on the support bracket and secure the three clamp nuts to 9 Nm (80 lb-in), then loosen the clamps for 720 degrees and tighten them to 7 Nm (62 lb-in). The EGR cooler support bracket requires the lower two bolts to reach 31 Nm (23 lb-ft) torque while completing the upper bolt and lower stud bolt torque to match 31 Nm (23 lb-ft). Republish the two power steering tube position retainers and tighten the nut to 25 Nm (18 lb-ft). Secure both EGR cooler upper parts with a torque of 31 Nm (23 lb-ft) and lower part nuts at the same torque value. Place the EGR valve coolant supply hose position retainer and fasten its nut at 12 Nm (9 lb-ft) torque while connecting the hose with a new clamp which requires a 4 Nm (35 lb-in) torque. Mount the cooling fan stator after connecting the EGRT sensor electrical connector while you also reposition the CAC tube with its clamp tightened to 8 Nm (71 lb-in). Install and secure the power steering reservoir with two bolts at 8 Nm (71 lb-in). After connecting the fuel cooler tube to the retainer on the power steering reservoir one should install the spring clip then add the upper radiator hose quick connect coupling followed by reinstalling the degas bottle assembly.

Question 2

How to conduct a leak test on the EGR Cooler on Ford F-350 Super Duty?

Accepted Answer

A leak test of the Exhaust Gas Recirculation (EGR) cooler requires you to install either the original mounting fasteners or buy M8 fasteners from a local vendor. The EGR cooler Test Plates must be installed at each end of the cooler using 4 M8 bolts with corresponding nuts which need tightening up to 31 Nm (23 lb-ft). During testing avoid applying a pressure greater than 207 kPa (30 psi) since high pressure will harm the EGR cooler. Activate the regulated air supply and rise the air pressure to 207 kPa (30 psi) before closing the supply. Dip the complete EGR cooler into water while examining for air bubbles to escape from the coolant paths. A new EGR cooler assembly becomes necessary if leaks are discovered in this process. Yet, if no leaks appear the assembly can be put back into service.

OEM Ford EGR Cooler

17 EGR Coolers found

Ford EGR Cooler Part Number: K2GZ-9F464-A

Ford EGR Cooler Part Number: 4C3Z-9P456-AJ

Ford EGR Cooler, Upper Part Number: 8C3Z-9P456-C

Ford EGR Cooler, Lower Part Number: 8C3Z-9F464-F

Ford Throttle Cable Part Number: E1TZ9F464A

Ford Cooler Part Number: ML3Z-9F464-C

Ford EGR Cooler Part Number: K2GZ-9F464-B

Ford EGR Cooler Part Number: LX6Z-9F464-C

Ford EGR Cooler Part Number: JT4Z-9F464-B

Ford EGR Cooler Part Number: CK4Z-9U433-D

Ford EGR Cooler Part Number: P2GZ-9F464-A

Ford EGR Cooler Part Number: LB5Z-9F464-C

Ford EGR Cooler Part Number: LB5Z-9F464-A

Ford Cooler Part Number: BC3Z-9F464-C

Ford Cooler Part Number: BC3Z-9F464-B

Ford Cooler Part Number: HC3Z-9V426-E

Ford Cooler Part Number: HC3Z-9V425-B

Ford EGR Cooler

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