Attention: TDR Forum Junkies I chose today to perform my service procedure on the EGR cooler and valve.
My truck reached 67,500 over the week end. And so I girded my loins for what I expected to be a tedious, dirty procedure. I was completely foxxed by the near complete lack of carbon build-up in the EGR or the cooler. It was like a very low mileage truck. I should note that I have seen an example of a severely carbon fouled EGR & cooler. The shop where I send our delivery trucks was doing the procedure when I stopped by, and I was able to see what lay in store for me. Or so I thought.
In aid of an explanation I consulted my service file for the truck. I knew I had had a new turbo at just over 35K and the service order mentioned cleaning the EGR. On the third page of the service order in one sentence there was the mention of replaced "Damaged Cooler" . Since I had all my warranty work done at the same dealer (Glen Thomas Dodge in Long Beach Ca. ) I called the service manager and inquired about the cooler. The mechanic had apparently broken a tube on the cooler in the process of removing the turbo. It was early days for said mechanic and he continued to make expensive errors. Suffice it to say he is no longer employed there.
Sadly this didn't save me a second of time, as I had made the discovery after I had fully diassembled the cooler from the engine.
I did however make a discovery regarding tools. As stated by many here, no special tools are required. Helpful mind,but not required. I caroused the local Pawnbrokers and found a candidate for a special 15mm wrench for the two back inside bolts that are somewhat difficult to remove and tighten. I bent the wrench to an advataeous angle which saved me a great deal of frustration and knuckle skin. Everything in that area appears to have been honed to an edge that would no doubt impress the entire population of Solingen Germany.
The reassembly went spledidly except that I very nearly forgot to install the new filter. The only thing that gave any trouble was the surreal "macarena" procedure for clearing the service message. It brought to mind the slot machine gag in Ocean's 13. After a few tries however, I mastered even that awkward little dance.
My truck reached 67,500 over the week end. And so I girded my loins for what I expected to be a tedious, dirty procedure. I was completely foxxed by the near complete lack of carbon build-up in the EGR or the cooler. It was like a very low mileage truck. I should note that I have seen an example of a severely carbon fouled EGR & cooler. The shop where I send our delivery trucks was doing the procedure when I stopped by, and I was able to see what lay in store for me. Or so I thought.
In aid of an explanation I consulted my service file for the truck. I knew I had had a new turbo at just over 35K and the service order mentioned cleaning the EGR. On the third page of the service order in one sentence there was the mention of replaced "Damaged Cooler" . Since I had all my warranty work done at the same dealer (Glen Thomas Dodge in Long Beach Ca. ) I called the service manager and inquired about the cooler. The mechanic had apparently broken a tube on the cooler in the process of removing the turbo. It was early days for said mechanic and he continued to make expensive errors. Suffice it to say he is no longer employed there.
Sadly this didn't save me a second of time, as I had made the discovery after I had fully diassembled the cooler from the engine.
I did however make a discovery regarding tools. As stated by many here, no special tools are required. Helpful mind,but not required. I caroused the local Pawnbrokers and found a candidate for a special 15mm wrench for the two back inside bolts that are somewhat difficult to remove and tighten. I bent the wrench to an advataeous angle which saved me a great deal of frustration and knuckle skin. Everything in that area appears to have been honed to an edge that would no doubt impress the entire population of Solingen Germany.
The reassembly went spledidly except that I very nearly forgot to install the new filter. The only thing that gave any trouble was the surreal "macarena" procedure for clearing the service message. It brought to mind the slot machine gag in Ocean's 13. After a few tries however, I mastered even that awkward little dance.
