EGR COOLER PRESSURE TEST KIT TIPS
Use the EGR Cooler Pressure Test Kit (J-54414) to check the Exhaust Gas Recirculation (EGR) cooler and assembly for pressure leaks on the 2016 TITAN XD Diesel. This Essential tool provides you with an inlet plug and an outlet plug for connecting an air pressure regulator and shut-off valve to pressure-test the EGR cooler. The EGR cooler is best serviced as an assembly.
Refer to the Electronic Service Manual (ESM) for EGR cooler and assembly removal, cleaning, and installation instructions.
Leak Inspection
Inspect for air escaping the EGR cooler and assembly components for leaks by performing a soap-and-water test. Spray the exterior of the cooler, all lines and all fittings with a mixture of soapy water.
Pressure Drop
Remove the EGR Cooler, install the plugs from the kit, connect an air pressure regulator and a shut-off valve.
Apply 50 psi of air pressure to the EGR cooler.
Measure and record the air pressure after 20 minutes:
- If there is no pressure drop, the EGR cooler is reusable.
- If the measured pressure drop is more than 20 psi (138 kPa), replace the EGR cooler.
- If the measured pressure drop is greater than 0.5 psi (3.45 kPa) on the second test and there are no air leaks found on the assembly, replace the EGR cooler.
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