EGR Cooler Repair Service Costs
6.0L Powerstroke EGR Cooler
Typical Labor Time:4-5 hours
Labor Cost:$500-625
Parts Cost:$300-450
Total Estimated Cost:$800-1,075
6.4L Powerstroke EGR Cooler
Typical Labor Time:5-6 hours
Labor Cost:$625-750
Parts Cost:$400-600
Total Estimated Cost:$1,025-1,350
6.7L Powerstroke EGR Cooler
Typical Labor Time:4-5 hours
Labor Cost:$500-625
Parts Cost:$450-700
Total Estimated Cost:$950-1,325
LB7 Duramax EGR Cooler
Typical Labor Time:3-4 hours
Labor Cost:$375-500
Parts Cost:$300-450
Total Estimated Cost:$675-950
LLY/LBZ Duramax EGR Cooler
Typical Labor Time:4-5 hours
Labor Cost:$500-625
Parts Cost:$350-500
Total Estimated Cost:$850-1,125
LML/L5P Duramax EGR Cooler
Typical Labor Time:5-6 hours
Labor Cost:$625-750
Parts Cost:$400-600
Total Estimated Cost:$1,025-1,350
Note: Prices are estimates and may vary based on vehicle condition, parts availability, and unforeseen complications. Additional parts or repairs may be necessary upon inspection.
EGR Cooler Repair Procedures by Vehicle Type
6.0L Ford Powerstroke EGR Cooler
Repair Steps:
- Drain coolant system
- Remove intake air ducting
- Disconnect and label electrical connections
- Remove EGR valve
- Remove oil filter housing
- Disconnect coolant lines from EGR cooler
- Remove EGR cooler mounting bolts
- Extract EGR cooler carefully
- Install new EGR cooler with new gaskets
- Reverse removal steps for reassembly
- Refill coolant and verify no leaks
6.7L Cummins EGR Cooler
Repair Steps:
- Drain cooling system
- Remove intake manifold
- Disconnect EGR valve electrical connector
- Remove EGR temperature sensor
- Disconnect coolant lines
- Remove EGR cooler mounting bolts
- Remove EGR cooler assembly
- Clean mounting surfaces thoroughly
- Install new EGR cooler with new gaskets
- Reassemble in reverse order
- Refill coolant and check for leaks
6.6L Duramax EGR Cooler
Repair Steps:
- Drain coolant system
- Remove engine cover
- Disconnect intake ducting
- Remove EGR valve
- Disconnect coolant lines from cooler
- Remove heat shields
- Remove EGR cooler mounting bolts
- Extract EGR cooler
- Clean all mounting surfaces
- Install new cooler with new gaskets
- Reassemble components
- Refill coolant and test system
Important Notes:
- Always use new gaskets and hardware when replacing EGR coolers
- Proper torque specifications must be followed
- Coolant must be properly bled from system after repair
- Diagnostic testing should be performed after repair
Note: These are general repair procedures. Specific steps may vary based on vehicle year, model, and configuration. Always consult the appropriate service manual for detailed instructions.
Understanding EGR Coolers
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Common EGR Cooler Failure Symptoms: Warning Signs You Shouldn't Ignore
EGR Cooler Failure Signs & Service Information
6.0L Powerstroke EGR Cooler
Common Signs of Failure:
- White smoke from exhaust (coolant burning)
- Coolant loss with no visible leaks
- Engine overheating
- Sweet smell from exhaust
- Low coolant warnings
Service Schedule: Inspection every 30,000 miles; replacement typically needed between 80,000-120,000 miles
6.7L Powerstroke EGR Cooler
Common Signs of Failure:
- Check Engine Light (P0401 code)
- Reduced engine performance
- Black smoke from exhaust
- Poor fuel economy
Service Schedule: Inspection every 50,000 miles; generally more reliable than 6.0L, replacement as needed
Duramax EGR Cooler
Common Signs of Failure:
- Engine running rough
- White exhaust smoke
- Coolant consumption
- DPF regeneration issues
- Check Engine Light
Service Schedule: Inspection every 40,000 miles; typical lifespan 100,000-150,000 miles
Cummins EGR Cooler
Common Signs of Failure:
- Loss of coolant
- White smoke at startup
- Rough idle
- Poor performance
- Engine overheating
Service Schedule: Inspection every 45,000 miles; replacement typically needed between 100,000-150,000 miles
Note: These are general guidelines. Actual service intervals may vary based on driving conditions, maintenance history, and specific engine applications. Always consult your vehicle's manual or a certified technician for specific recommendations.
How It Works
- Get a quote online or set-up a time to have your vehicle looked at.
- Pick time slots that work for you, easily, online.
- We will confirm appointments and send reminders.
- Our mechanics bring everything that is needed to you.
- All you have to do is provided a safe area for the work to be performed.
What we need from you
- A safe place to work on your vehicle
- No working on the side of busy roads
- No working on unstable or steep surfaces.
- We do not perform repairs during severe weather.
- Authorization from a property owner or management.
- Repair work done in a parking lot or at your requires permission.
- We do not do repairs in areas restricted by law.
Common Questions
Service Area
Our primary service area is greater Grand Rapids and includes Comstock Park, East Grand Rapids, Grandville, Kentwood, Walker, and Wyoming
Our secondary service area is provided by our Belding location and includes: Belding, Greenville, Ionia and the sorrounding areas.
Contact us if you have any questions about where we provide services.
