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Egr Cooler Comparison

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In this comparison you can see the difference in EGR coolers between the ’03 and ’04-to-’07 model years. The circular design on the ’03-style coolers (bottom) is less prone to plugging up from carbon, oil, and soot buildup than the rectangular-style ’04-and-newer coolers (top). Another common failure on EGR coolers is due to the coolant core seam leaking, which allows coolant to enter the exhaust stream (up into the turbo), or into the intake when the EGR valve is open.