Several car models are equipped with an EGR cooler for cooling the exhaust gas which is supplied to the EGR valve. Although the EGR valve and EGR cooler often are combined into one unit, the EGR cooler can often be replaced separately, in cases where it has become leaky. We are now launching a comprehensive programme of more than 60 EGR coolers in OE quality.
EGR cooler (ref. no. 881310104) for i.a. Citroën, Fiat Ford, Peugeot and Volvo
A leaky EGR cooler can cause significant damage to the engine - including the turbocharger - and in some cases even cause fire in the intake manifold. It is therefore important that it will be replaced immediately, in cases where leaks have occurred. But it can be difficult to detect a leak in an EGR cooler, because the leak rarely appears by clear or outer signs.
Citroën DS5 is one of the many models for which we have an EGR cooler
The following procedure may be used:
1. If possible, try to do a visual inspection of the output of the EGR cooler with an endoscope. If the soot deposit seems damp, it indicates a leak
2. Perform a pressure test on the radiator system for both hot and cold engine with 1.5 bar
3. If the pressure drop after 10 minutes is greater than 0.2 bar, it indicates a leak
4. If there are no signs of an outer leak, it indicates that you might have a leaky EGR cooler
Alternative control - only for cars where it is possible to disconnect entry and exit:
1. Dismount the EGR cooler without disconnecting it from the cooling system
2. Put the cooling system under 1.5 bar pressure
3. Blow compressed air into one of the open ends of the EGR-valve and observe if droplets of coolant are coming out at the other end
Pay particular attention to BMW diesel engines
Several owners of BMW models with engine code B47x, N47x and N57x (4 and 6 cylinder diesel engines produced from 2012-2017) have experienced various problems with:
- Smell of burnt plastic
- The engine misfires during acceleration
- The intake manifold melts in several places
- Engine control stores fault code 290A00 - The measured air mass is too high compared to the calculated air mass
The problem typically arises when the EGR cooler becomes leaky and leaks coolant into the intake manifold. The penetrating coolant causes soot in the manifold to dissolve. When the dissolved soot mass becomes hot - e.g. during highway driving - it can ignite and start a fire in the intake manifold.
BMW offers EGR cooler replacement, inspection and cleaning of the intake system, as well as software update and in some cases manifold replacement. BMW's offer applies to all 4 cylinder engines produced 04/2015-09/2016 and 6 cylinder engines produced 07/2012-06/2015. However, problems have also been seen on models beyond the affected production dates.
Due to the problems above and the quite severe consequences a failure can have, we have chosen not to include the EGR cooler in question in our programme. We recommend that garages refer customers to BMW.