6.7L PowerStroke EGR Cooler Replacement

  1. Begin by draining the primary and secondary cooling systems. The radiators have petcocks (one on drives side, one on passenger side respectively) to allow draining. Even though the coolant used is the same on each system, be sure not to cross contaminate if reusing drained coolant for refilling.
  2. Now starts the way I do it.. Disconnect the PCM, unbolt the bracket and remove, unbolt the PCM and remove. The harness is attached to the bracket by push pins
  3. Remove the hoses from the EGR cooler. There is 2 large hoses on top, one smaller hose on top, one smaller hose in the front. Just squeeze the clamp and position it higher on the hose.
  4. Remove the coolant hose from the T coming from the intake. Becareful, the plastic T is fragile. Then remove the T from the coolant pipe by squeezing quick connect clips.
  5. Position all hoses aside.
  6. Remove the plastic intake tube and filter cover.
  7. Unbolt all 4 bolts to the front exhaust crossover pipe and let it hang out of the way with the temp sensor remained plugged in.
  8. Unbolt and remove the exhaust manifold to cooler exhaust pipe. It does have a 5th bolt in the center for support. The bolts that attach it to the exhaust manifold are notorious for breaking lately as these engines age. Attempt removal. 3/8 Impact is recommended to aid removal. If bolt does not turn easily, try the other bolt. If one bolt is removed and the other only turns slightly but allows the pipe some movement, leave it and continue to follow remaining steps for removal of the EGR cooler and try to swing the exhaust pipe out of your way. If both bolts will not twist easily, prepare to break them and drill and tap the holes.
  9. Reach to the back of the EGR cooler and unplug the exhaust back pressure sensor, remove the harness attachment from the stud in the top right corner. With a short 10mm ratcheting wrench, loosen the EBP sensor bracket nut approximately 10 full turns but make sure only the nut is loosening and not the stud. If the stud is also turning, use a 13mm wrench to hold it. (Picture).
  10. Push and pull up on the EBP sensor bracket to get it off the stud. It is slotted.
  11. Remove the two push pins holding the passenger side injector insulator to the EGR cooler housing.
  12. Remove the two 10mm bolts attaching the main engine harness to the front of the EGR cooler housing.
  13. Unplug the connectors and vacuum lines on the front of the EGR cooler housing.
  14. Remove all 7 bolts attachment bolts on top of the cooler. 3 bolts on each side, one in the middle.
  15. Pull up on the EGR cooler housing. It rides on dowels and sometimes is hard to break loose of the valve cover/intake manifold runners.