Replace the EGR cooler on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including coolant drainage, EGR system disassembly, and gasket replacement.

Warnings

Tools required

Parts

• EGR cooler assembly × 1 — Use OEM specification
• EGR cooler gasket kit × 1 — Includes inlet/outlet gaskets
• EGR valve gasket × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Use OEM specification

Fluids

• Mopar OAT Coolant (Purple) — 4 qt

Preparation

1. Ensure engine is completely cold (wait minimum 4 hours after last operation)
2. Park vehicle on level surface and engage parking brake
3. Disconnect both negative and positive battery terminals to prevent electrical issues during repair
4. Place coolant drain pan under radiator petcock
5. Remove engine cover by lifting upward from rear clips
6. Take photos of EGR system connections and routing for reference during reassembly

Procedure

1. 1

   Drain cooling system
   Open radiator petcock at bottom of radiator to drain coolant into drain pan. Once flow stops, locate and open engine block drain plug on driver side of engine block to completely drain coolant from engine. Collect all coolant for proper disposal or reuse if uncontaminated.
   ⚠Coolant is toxic to animals and children. Store drained coolant in sealed container away from access.
2. 2

   Remove air intake components
   Loosen clamps and remove air intake tube from turbocharger inlet to air filter housing. Disconnect any sensors attached to intake tube. Remove complete intake assembly to provide access to EGR system. Set aside in clean area.
3. 3

   Disconnect EGR valve
   Disconnect electrical connector from EGR valve by pressing release tab. Remove mounting bolts securing EGR valve to EGR cooler outlet. Carefully separate EGR valve from cooler, noting orientation. Remove and discard old gasket.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
4. 4

   Remove EGR cooler coolant lines
   Locate coolant inlet and outlet hoses connected to EGR cooler. Use appropriate size socket to loosen hose clamps. Carefully twist and pull hoses off EGR cooler nipples. Some residual coolant will drain, so keep drain pan positioned below. Inspect hoses for cracks or deterioration and replace if necessary.
   ℹ️Mark coolant hose positions with tape or photos to ensure correct reinstallation.
5. 5

   Disconnect upstream oxygen sensor
   Locate upstream oxygen sensor in exhaust pipe before turbocharger. Disconnect electrical connector. Using O2 sensor socket or 22mm wrench, carefully unthread sensor from exhaust pipe. Inspect sensor threads and replace if damaged or excessive carbon buildup present.
   ⚠Do not use excessive force on oxygen sensor. If seized, apply penetrating oil and allow to soak before retry.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
6. 6

   Remove exhaust inlet connection
   Locate exhaust pipe flange connection at EGR cooler inlet. Remove exhaust flange bolts securing exhaust pipe to EGR cooler. Support exhaust pipe to prevent strain on downstream connections. Separate flange and remove old gasket completely.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
7. 7

   Remove heat shields
   Remove heat shield bolts securing protective shields around EGR cooler. There may be multiple shields depending on configuration. Carefully remove shields and set aside for reinstallation. Note orientation and position of each shield.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
8. 8

   Remove EGR cooler mounting hardware
   Locate all mounting bolts and brackets securing EGR cooler to engine block and cylinder head. Remove mounting bolts in sequence, supporting cooler weight. Remove any additional brackets or hanger bolts that secure cooler assembly.
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)

   Hanger Bolts27 Nm (20 lb-ft)
9. 9

   Remove EGR cooler assembly
   With all connections and mounting hardware removed, carefully maneuver EGR cooler out of engine bay. May require tilting or rotating to clear surrounding components. Exercise caution not to damage surrounding sensors, wiring, or cooling system components during removal.
   ℹ️EGR cooler is heavy and awkward to handle. Consider having assistant help with removal and installation.
10. 10

    Clean mounting surfaces
    Using gasket scraper and wire brush, thoroughly clean all gasket mating surfaces on engine block, cylinder head, and exhaust connections. Remove all traces of old gasket material, carbon deposits, and corrosion. Wipe surfaces clean with shop rags. Inspect for cracks, warping, or damage that could cause leaks.
    ⚠Do not gouge or scratch sealing surfaces. Deep scratches will prevent proper gasket seal.
11. 11

    Prepare and install new EGR cooler
    Unpack new EGR cooler and verify all ports match original. Install new gaskets on cooler inlet and outlet flanges per gasket manufacturer instructions (do not reuse old gaskets). Apply thin coat of anti-seize to all mounting bolt threads except those entering aluminum. Carefully position new EGR cooler into mounting location, aligning all mounting holes.
12. 12

    Install mounting hardware and connections
    Install and hand-tighten all mounting bolts and hanger bolts to secure EGR cooler. Torque mounting bolts and hanger bolts to specification in crisscross pattern. Reconnect exhaust inlet flange with new gasket, applying anti-seize to exhaust flange bolt threads, then torque to specification. Reinstall heat shields and torque heat shield bolts to specification.
    Torque spec

    Mounting Bolts37 Nm (27 lb-ft)

    Hanger Bolts27 Nm (20 lb-ft)

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)
13. 13

    Reinstall oxygen sensor and EGR valve
    Apply anti-seize compound to oxygen sensor threads only (avoid getting anti-seize on sensor tip). Thread O2 sensor into exhaust pipe and torque to specification. Reconnect O2 sensor electrical connector. Install new EGR valve gasket on EGR cooler outlet. Position EGR valve and install mounting bolts, torquing to specification. Reconnect EGR valve electrical connector.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)

    Mounting Bolts37 Nm (27 lb-ft)
14. 14

    Reconnect coolant lines and refill system
    Reconnect coolant inlet and outlet hoses to EGR cooler nipples, ensuring hoses are fully seated. Tighten hose clamps securely. Close radiator petcock and engine block drain plug. Refill cooling system with Mopar OAT Purple coolant through radiator cap or overflow reservoir until full. Squeeze upper radiator hose to help purge air from system.
    ℹ️Cummins diesel cooling system requires proper bleeding procedure to prevent air pockets.
15. 15

    Reinstall intake and complete assembly
    Reinstall air intake assembly in reverse order of removal, ensuring all clamps are tight and sensors reconnected. Reinstall engine cover. Reconnect battery terminals (positive first, then negative). Start engine and allow to warm to operating temperature while monitoring for coolant leaks around EGR cooler connections. Check coolant level once engine reaches temperature and top off as needed.
    ⚠Monitor closely for coolant or exhaust leaks during first test run. Shut down immediately if leaks detected.

Reassembly

1. Torque all fasteners to specification using proper sequence
2. Apply anti-seize compound only where specified in procedure
3. Use only new gaskets - never reuse exhaust or coolant gaskets
4. Double-check all electrical connectors are fully seated with locking tabs engaged
5. Verify no tools or rags left in engine bay before starting engine

Verification

• Start engine and verify no coolant leaks at EGR cooler connections
• Check for exhaust leaks at EGR cooler inlet flange (listen for hissing)
• Verify coolant level is correct after engine reaches operating temperature
• Use scan tool to verify no EGR system diagnostic trouble codes present
• Confirm EGR valve operates properly by monitoring data stream during test drive
• Recheck all connection points after 50-100 miles of driving and retorque if necessary
• Monitor coolant level for several days after repair to ensure no slow leaks present

More procedures for this vehicle