An EGR (Exhaust Gas Recirculation) Cooler is a heat exchanger installed in the EGR circuit. The EGR system recirculates exhaust back to the engine in order to reduce NOX (Nitrous Oxide) emissions. The cooler simply cools the exhaust gas prior to gas being reintroduced into the engine. By cooling the gas the combustion temperature is reduced and NOX also as NOX is formed at higher temperatures. Various cooler (heat exchanger) technologies are used by manufacturers, although tube and shell is the most common type used currently. Coolers will vary in size depending on the engine size and the emission standard the engine must comply with.
8-10 hrs as much as 13 hrs depending on what all went wrong with it. Oil cooler should be replaced at the same time if egr cooler failed. that includes R&R of egr cooler, Oil cooler and some time to flush and refill cooling system and oil change or venting of water from cylinders.
remove turbo and intake then remove cooler from under side of intake.
I have replaced too many to count ever sense the egr cooler's were introduced in mid 03. The reason the coolers are blowing is caused by heat restricted oil coolers. It is located right in the valley. Ford now recommends replacement of the oil cooler because the coolant is first pumped to the oil cooler then a direct path to the egr cooler. Well we finally figured that the oil cooler's become restricted due to lack of maintenence (coolant) and or just because. So the lack of coolant flowing threw the oil cooler starved the egr of coolant and it's cooling abilities so then the welds inside the cooler melt and fracture causing coolant and water to enter the intake and exhaust system. Our shop charges 15-16 hours to do the job at 110 an hour. This includes both the oil cooler, egr cooler, steam cleaning of intake to remove carbon build up, and cleaning the rusty turbo due to the water entering it. The cost of the parts can vary and the repair costs about $3300-4000. How this is the only way to do it. If you just replace the egr cooler and not the oil cooler you will not be correcting the main cause. In turn paying for it twice maybe three times. If the egr cooler is just replaced about $1000-1200 Maybe less due to parts. Labor would be about 6.5-7 hr. Well do it right the first time and you won't be wasting money down the road. Good luck Powerstroke57
99 percent of the time it is the egr cooler. There was a recal on it look for the update verson of the cooler and have it replaced.. Tj
Yes. My 2004 F-250 6.0 Powerstroke's EGR cooler also just failed at 34,820 miles. Took it to Ford today. Last November the exhaust system failed and crankcase gaskets started leaking, cost Ford $2,250.00 of warranty to fix. Now the EGR cooler. What's next?
If you can't locate a leak, inspect the EGR cooler.
Check the EGR cooler.
How to Diagnose a Bad EGR Cooler: This method is easy to do and is a good "test" if you have any of the three symptoms above. To do this test, turn off your rig. When its all cooled down, remove the EGR valve (between your alternator and oil filter - it looks like a 7-ounce beer can with wires going to it) and look inside with a flash light. If it looks wet, gooey or steam cleaned, then you probably have EGR cooler problems.
It fits the 460 hp E7 engine from the 2002 to 2007 model years.
EGR Deactivated ( Plugged? ) NOX exceeds allowable spec. NOX are Oxides of Nitrogen and nasty smog causing junk. Common for this year to plug the EGR cooler or have an EGR failure. This is also one of the codes you run into if you don't do your emissions delete correctly.
Right side of the engine, in front of the EGR cooler and connected to it with through a bellows. Removing it.. depends on the make and model of truck. On the Kenworth T600, T660, T700, T800, etc., you have to remove the CAC hose and hose from the air cleaner to the turbo inlet. Then you remove the three bolts to take off the plate covering the EGR valve, remove the two EGR clamps (one to the left, connected to the bellows, and one at the top of the EGR), drain the coolant and disconnect the two coolant lines to the EGR valve, unplug the EGR valve, and remove it.
yes, the egr valve (Exhaust Gas Recirculation) device is there to help reduce emissions by resending unburnt fuel and harmful gasses back through the cycle. This also helps the engine burn leaner and cooler.