6.7L Cummins Forum

morbid, thanks a lot, i see exactly what you are talking about. i appreciate your time in responding.

I just cleaned the egr valve and the cooler. I have detail pictures of the valve if anyone is interested. The valve went well, 20mins off and on, 1 hour in cleaning solution. Piece of cake. The cooler on the other hand was a pain. Right side manifold nut was a bear. Got it off, thankfully it fell through the engine and trans bell. This nut is not magnetic by the way. I’ll be putting it all back together tomorrow morning. I had to let it dry out over night as it was late when I rinsed it.

I already have that pain in the a&^% nut wedged in the deep socket to put it back on tomorrow morning. If anyone knows of a better way to reach back there for that nut, please let me know. I was cussing some Dodge Engineers over that one.

I want to thank both Squid and Morbius for the tips and tricks. I too have pictures of the whole affair. I wasn't in a rush so I guess the whole process took about 4-5 hours of me mucking around in the garage. Using the pdf that Morbius posted, I went and did a search for the sequence of getting the cooler and valve off. I could not find an exact match. What I did find that was useful was a guide to installing a 'Delete' kits. This step by step at least gave me a good idea of the sequence of removal. I then used the clean procedure without a hitch.
Here are some notes from my experience. My truck is from Canada and I got it used Oct 2010 (its an 08). Not knowing how the truck was driven previously I was surprised that the Perform Service indication came on so early. Having said that I think there may be a bug in the EVIC. Since my indication came on between 67000 and 70000 kms, the system may be in miles and therefore set prematurely. For those of you that own a Canadian truck that is clocked in kilometers this may be useful.
I found that the cooler, after the 1 hour soak in the solution, had lots of loose exhaust particles. So my recommendation is to rinse with hot clean water and when you are finished...rinse it again.
Without a torque spec for the 10 mm studs, I used 360 in/lbs. In hindsight this is likely a little too snug (they won't come off that's for sure). 300 in/lbs (25 ft/lbs) is likely a better setting. The two 15 mm nuts that hold the cooler flange at the back are just a little too far in to get a proper torque on so I made them 'real tight' using the back end of a 22 mm spanner to help with some more leverage on the end of the 3/8" socket wrench.
I also found that for the little extra effort of removing the air intake there was more room to access the lower side to remove the EGR cooler housing.
I got my kit from Steve White Motors (ebay). They shipped right away. I still have to follow up with them as the kit was missing one gasket for the EGR Valve. Fortunately the old gaskets were in good shape and I was able to re-install without issue. Note to self in the future...make sure all the parts are in the box!

A little additional heads for all. I was looking around on ebay and have several complete EGR (with motor) and coolers (with valves) going real cheap so far (under $50 USD). I have found having a spare on the shelf ready to go speeds the process very nicely and allows you to soak the units you removed over night at least. Also other benefit is it allows me to pressure test the cooler over night. With spares on hand, its a less than hour process and off you go

You are all most welcome, anything we can do to help others and keep this great trucks running like a champ !! Great idea about looking at delete docs for more tips on doing the maintenance !!

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Curious had my 09 in at 35,000 miles because my exhaust brake was not working properly they cleaned egr and then replaced egr and turbo. I only use my truck to pull my 11,000 lb 5th wheel for work so its duty cycles are work mode. My truck now has 52,000 miles and I am wondering when it would be advisable to perform egr and cooler cleaning.

Thanks Bill

How would you know if it needed cleaned

Thanks for the info on cleaning. Will let you know how it goes.