EGR Cooler Leak Test

First perform a cooling system pressure test. Refer to PRESSURE TESTER METHOD .
NOTE:
If the cooling system has been losing coolant and there are no external leaks showing, the Exhaust Gas Recirculation (EGR) cooler may be leaking internally.
If the leak has not been found, using this method, it may be necessary to remove the EGR cooler and perform a bench test.

Courtesy of CHRYSLER GROUP, LLC
Install a plug into the EGR cooler coolant inlet port (1) and outlet port (3).
In the smaller inlet port (2), install the vacuum test adapter.
NOTE:
The plug and the adapter must have an air tight fit to prevent misdiagnosis.
Pump up the commercially available vacuum tool, while observing the pressure gauge, the vacuum should remain steady.
If the EGR cooler does not hold a vacuum, the EGR cooler has an internal leak and must be replaced.
If the EGR cooler holds vacuum, then refer to the engine internal leakage inspection. Refer to DIAGNOSIS AND TESTING .