Part 1/3: Dodge Ram Cummins 6.7 diesel EGR cooler removal and cleaning

everyone this is David fighting motor city mechanic today I've got a coming 6.7 liter in the shop and I want to show you step-by-step how to remove and clean the EGR cooler now there's a couple of reasons why you may want to take it off when is the cleaning of course that's done every sixty seven thousand five hundred miles and you'll get a poem service light on inside it says that and the second would be if you've got a problem with the cooler itself which it can rupture from time to time it's very rare but it does happen and when that happens you get cooling into the exhaust nonetheless the procedure is exactly the same for both the only difference is on the cleaning I'm going to show you about adding the fluid and making sure that you rinse it out properly and have time to drive before you put it back on so with that let's get ready to check it out hi so you're not gonna be able to get the EGR valve off or the crankcase filter assembly or the EGR cooler unless you get the plastic engine shroud off now I want to get it off is fairly cut and dry you got your dipstick you've got to pull out once you pull it out you got a total of four eight millimeter bolts here here here and here once we get those off we'll be able to get it out of the way then we'll have access to if you're going to be doing the EGR cleaning if you're going to be replaced the crankcase filter or the EGR cooler whichever one of the three combinations you're going to be doing we'll be able to have access now all right there you go last bolt and we got the dipstick out of the way so we hadn't set the cover off to the side now we got access to everything is on top of the engine without anything being on our way so you're free to do any kind of work you need to on the gr cooler which we're going to you can replace the crankcase filter easily now and you can also take your belt off if you need to all right so the EGR cooler is located back here on the passenger side of the engine now it's located for the back is part of the manifold assembly you've got a section back here you've got to get to the back bolt and it comes up to here right where this control valve is so you do have a few things you need to get out of the way now one thing to help you get to a few things I do recommend taking the rubber boot off from the air filter down to the turbo just gives me a little more room I'd probably go ahead and tell you to go in and recommend disconnecting both negative cables on the batteries because you will be working in this location you don't want arc up against the positive battery cable so go ahead and disconnect your batteries take the air inlet off once we get the air aloft off we'll start working on proceeding with the EGR cooler so litter air cleaner assembly is held on with two latches let's go ahead and grab them Lisa I'm gonna pick up and you want to slide it off the little portion back here towards engine has the fingers that go into the law block to keep it in place now we do got two connectors up here we need to go ahead and disconnect we'll go ahead and squeeze in on the connector on the first one it has one lock the secondary one back here has two-stage lock it's got a red piece you need to squeeze in on and you need to pull it off in order to release that connector did you do usually by use your finger do it if it's down there while in kind of dust and dirt may use screwdriver push it up on the red lock once it's all the way flushes bobbin its protruded top then you squeeze on the secondary lock squeeze on it slide it out of the way now the harness is still attached to the air filter assembly by a little plastic Christmas tree fastener here we'll pull that off and get it out of the way here's a rubber hose that we just took loose from the air inlet going up to the crankcase filter you got that out of the way now here's your oversized band clamp right here that has a beta actually secures the air inlet to the turbo you go back off the screw there and once you get that loose will be all the wiggle is simply off obviously just go ahead and grab up here at the filter I put my hand a little further down where it gets close to that turbo and just start wiggling once I get it up and she'll lift up and I can get it and sit it out of the way so there you go you got it loose just put it on the ground next to where you work ice let me give you a little breakdown on how it mounts now we do have a clamp up here the V band type clamp that mounts to the front of the EGR cooler and you got a total of four bolts that go through the midsection going down to the bracket on the exhaust manifold and then at the rear you've got two nuts there's a studs that come up off the manifold and you get to nuts you've got to take loose on the back the back are gonna be 15 millimeters and then the four up here are going to be ten millimeters and that van clamps gonna be an 11 millimeter now keep in mind we've still got a few things mounted to the outside of here we got some coolant hoses we got one at the rear here we got one at the front here and then we also got this EGR control valve assembly that we're gonna have to take loose that's probably gonna be our next step right here now it's got that two-stage lock like I told you about earlier on the air inlet here we gotta lift up on on the primary lock squeeze down secondary roots inside now we're not gonna take the cables loose we're gonna leave all that there now we got two ten millimeters on the side here and we got to ten millimeters on the back span between the valve cover we need to get off to get this assembly off and another thing that's gonna be partially in your way is this coolant pipe there's actually a bolt right here we'll be taking off as well and I'll show you that in just second I some spray some wd-40 up in here where that hose that pipe goes on the cooler get up in there get soaked down guys when it gets loosen up it be good to go I went ahead and took the ten millimeter off the bracket for the hose and I also took the two ten millimeters off on this side and go to eg our control valve bracket so once I've got to lube in there I can start wiggling a little bit to get it loose and pull it all the way back to it finally comes off and I give you enough clearance to do what you need if you need to move it out of the way you can it does have a braided flexible line on it so it helps you like I said now all I gotta do is move up to the back side to get to the two ten millimeters on this side high so for reference Burton so here's your valve cover it upper portion assembly and here's the side this is electrical portion of that EGR control valve and flow valve now you got the two tens here in here that's the last twenty to take loose and get this bracket and assembly positioned out of the way so go ahead and knock them out real fast all the bolts are off now we go ahead and move this assembly I get the electrical connector off now what we're going to do is like I said don't worry about this cable assembly that's going to stay now you'll notice some time time there's a spring that goes from this bracket 200 is cable mounts right here now you'll see that spring broke from time to time it's nothing to worry about that's just something that's installed her at the factory when they put an engine together they even tell us to crush it do not be worried about don't worry about replacing anything if it's broke it's not a problem and what I need to do is I need to lift up and get it up out of the way because I still got a clear where it goes around the neck of that where that coolant mounted and you have to squeeze a little bit because you got that spring to overcoming these cables and then what I do is I just set it to the side because now it's it's no longer in my way is everything from here back is EGR cooler so now I can work on getting this crankcase hose out of the way and then I can work on getting this coolant hose off because there's a nipple that goes into the head straight down I need to get these off that way I got a little more clearance to get into the bolts because like I said there's four bolts that hold down the cooler in the midsection right here you

Channel: MotorCity Mechanic

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Keywords: Ram Pickup (Automobile Model), Diesel Engine (Engine Category), Cummins (Business Operation), Exhaust Gas Recirculation, Pickup Truck (Automotive Class), Ram Trucks (Brand), Dodge, Chrysler, cummins 6.7, diesel, Automobile (TV Genre), motorcity mechanic, auto parts, how to, diy, auto repair, repair, parts, Ram, EGR cooler, cooler

Id: kGotr1QMwCA

Length: 7min 55sec (475 seconds)

Published: Wed May 27 2015