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STEP 1
Pressurize the cooling system and inspect for obvious external leaks.
STEP 2
Remove the EGR valve and inspect it to see if it looks wet and shiny. If the EGR valve is located after the EGR cooler, coolant leaks will wet the valve. EGR valves on the hot side of the EGR system will not become wetted with coolant.
STEP 3
With the cooling system pressurized, disconnect the outlet pipe of the cooler and check for visible leaks.
STEP 4
Disconnect the EGR cooler inlet and outlet exhaust pipe. Using a block-off kit with a pressure adapter, plug the exhaust inlet and outlets and tighten the block-off plate adapters using the EGR clamps.
STEP 5
Pressurize the exhaust side of the EGR cooler using the block-off kit with shop air supplied at 30 psi (207 kPa).
STEP 6
Shut off the compressed air to the cooler while it is pressurized and wait 30 minutes. There should be no pressure drop in 30 minutes. Any drop indicates that the cooler is defective.
STEP 7
Check for air bubbles in the surge tank and from the vent lines. If air bubbles are present, replace the EGR cooler.
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