The EGR cooler lowers the temperature of recirculated exhaust gas before it re-enters the intake, and it is one of the most common failure points on modern diesels.
What it does
To reduce emissions, diesels route some exhaust back into the intake. That gas is very hot, so the EGR cooler passes engine coolant around it to cool it down. This puts the cooler in a brutal environment of hot exhaust and coolant, separated by thin metal.
Signs it is failing
- Coolant loss with no external leak
- White smoke and a sweet smell
- Overheating under load
- Bubbling in the coolant reservoir
Replacement and what to know
Constant thermal cycling and soot loading eventually crack or clog the cooler, letting exhaust and coolant mix. Replacement with a quality unit, plus inspection of the EGR valve and a healthy cooling system, is the fix. On the 6.0L Power Stroke the oil cooler should be addressed at the same time.
Frequently asked questions
Why do EGR coolers fail?
Thermal cycling between hot exhaust and coolant, plus soot loading, cracks or clogs the internal passages over time.
What happens when it fails?
Exhaust and coolant mix, causing coolant loss, white smoke, and overheating.
Should I replace related parts?
Inspect the EGR valve and cooling system, and on the 6.0L Power Stroke replace the oil cooler at the same time.
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