Leaky EGR Cooler hose (Orange one) - Ford Powerstroke Diesel Forum
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Old 12-04-2007, 02:52 PM
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Leaky EGR Cooler hose (Orange one)

I have a 2003 6.0. I get an occasional drip spot under the engine on the passenger side. A smell and taste test indicates coolent. Further investigation found a leaky EGR coolent hose (the orange one under the turbo). Solution... Change the hose. Seems like an easy repair job doesn't it? After several hours of knuckle busting, I got the turbo loose but can't get it out of the engine compartment. Its totally loose and I can pick it up but I can't figure out how to wiggly it out.

What else do I have to remove to get the turbo out and then get to the EGR cooler hose? Any suggesitons??
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Old 12-04-2007, 03:40 PM
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I got some tech books and I will look into it and scan and send it to you but it wont be for a few hours I'm working hard on OT tonight Ill be in touch
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Old 12-04-2007, 04:52 PM
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OK, I got the turbo out. I had forgotten that the rear of the engine was lowered on a jack. Once it was raised up to proper attitude the turbo came right out. The jack is holding up the rear of the engine because I had to remove the rear cross member so the exhaust pipe could be lowered away from the turbo. The third bolt on the turbo was impossible to reach otherwise.

Now I can’t get the orange connector hose loose from the oil cooler. I cut the hose and was able to get one part off the EGR coolant tube. I can’t get the other half off the oil cooler. I removed the two Torx bolts from the cooler where the coolant line connects. I removed the small cover. I can’t seem to get the body of the connector of of the oil cooler. Its loose but won’t come off.

Once this connector body is off I can remove the remaining piece of the orange coolant connector hose and start the reassembly process.
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Old 12-04-2007, 08:48 PM
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Would it interest you that Ford pays a tech the princely sum of 1 (one) hour to perform that repair? Damned stealerships, anyway....
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Old 12-05-2007, 05:25 PM
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you need to twist it to line up the two internal tabs and it will slide off.look inside the new hose I believe the tabs must be at 9 and 3 to slip off.
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Old 12-05-2007, 08:19 PM
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Well I think I figured it out.

After I got the turbo and its mounting plate off, I was able to gain access to the EGR cooler pipe and the connector hose. I cut the hose with a knife and the end that was on the EGR cooler pipe came right off. The other end was a bit more tricky. Yes there are two little tabs at 9 and 3 oclock that would disengage from the flange on the oil cooler. The whole problem was I couldn't apply twist action and pull at the same time with the turbo installed, There just wasn't enough room. So... off came the turbo. (ha)

In hind sight, I suppose that it would be possible to remove the two torx bolts on the oil cooler flange and slip the EGR connector and the flange out together and then remove the connector hose from the flange after they are both off the engine. The new hose could be slipped on and the flange reinstalled. In theory this would probably work. However, when I took the old hose off the EGR pipe there was some residue from the old o-ring seals and a bit of corosion. If I hadn't removed the turbo I never would have seen the problem and the new hose probably would have leaked. I cleaned up the EGR pipe and oil cooler flange with some steel wool so the new o-rings would have a nice clean sealing surface.

After everything was reinstalled I pressure tested the coolant system with 15 psi of air. The filler cap pressure relief started venting at 16 psi just as it should. I let the test pressure stay for several minutes with no drop in pressure so I figured that there are no leaks. Then I filled the coolant system and started the engine. No water leaks but I did have an oil leak on top of the turbo. I should have put a new gasket under the oil supply flange. Oh well... live and learn!!
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Old 12-06-2007, 04:55 AM
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Great job getting it apart and back together.
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Old 12-07-2007, 03:37 PM
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Glad to hear you got it done Sorry I didn't come through on the manual I got called in to work and have not had time to stop and get it for you all week Maybe next time
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