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Old 10-08-2007, 04:51 PM   #1 (permalink)
GregH
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Join Date: Sep 2005
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EGR cooler hose replacement - with pictures

Here is how to replace the orange EGR cooler hose without removing the intake manifold or EGR cooler.

Start by identifying the leak. This leak is usually present for a short time after the engine has fully cooled down. A few drops of coolant will appear to be dripping off the lower rear corner of the right cylinder head.

Look for coolant below the orange hose

If you've got coolant here, then take out the turbo and pedestal.

Turbo and pedestal out

Drain out some coolant, so when you disconnect the EGR cooler hose you won't dump coolant everywhere.

Turn the hose so the "1" symbol is straight up
Slide the hose straight back
Have these two o-rings on hand
Note: the cover may be a bit difficult to get off. Work it side to side to keep from breaking anything. If you get medieval with it, the cover will break.

Install the two new o-rings along with your new EGR cooler hose (it will be blue) and put 'er all back together...

Beer time...

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