Fix leaking EGR coolers, improve engine and system performance, and avoid costly damages.
Built for demanding roads, our replacement radiators are hot-shake tested to withstand the toughest conditions.
Reusing sealing components risks early failure. Our kits include all gaskets and mounting hardware, with matching flow valves available where needed.
The housing makes up to 70% of an EGR cooler’s material. Repairing instead of replacing saves cost, resources, and environmental impact.
The EGR system - Exhaust Gas Recirculation - is a key component in reducing harmful emissions from the engine.
It works by recirculating a controlled portion of exhaust gas back into the engine’s intake. By replacing some of the fresh, oxygen-rich air with already combusted exhaust gas, the combustion process becomes less intense, lowering peak temperatures and thereby reducing the formation of NOX (nitrogen oxides) before the exhaust reaches the aftertreatment system - and takes some of the workload off the SCR system.
There is a trade-off though: Replacing fresh, cold air with hot, polluted exhaust gas reduces engine efficiency and performance.
As a mitigation, the recirculated gas goes through the EGR cooler before mixing with the intake air, to reduce the effect on engine performance. But still, flow of recirculated gas must be continuously regulated by the ECU, through the EGR valve:
More recirculation:
Less engine power and efficiency, and more fuel consumption.
Less recirculation:
More engine efficiency, but also increased AdBlue® consumption for the SCR system to compensate.
The efficiency of the EGR cooler is critical for both engine performance and SCR & AdBlue® efficiency. But EGR coolers can fail, and when they do, it often causes leakage of coolant into the exhaust stream.
This not only lowers cooling performance, but also affects engine efficiency and in severe cases may damage the Emission System.
As an example, more than half of DPF failures that we see at Dinex, are caused by leaking coolant liquid.
Recognizing the early warning signs of a leaking EGR cooler, is key to preventing further damage and avoiding unnecessary downtime. Below are the most common symptoms to watch for:
Coolant loss
If you find yourself topping up coolant more frequently than usual, it may indicate an internal leak in the EGR cooler, allowing coolant to escape into the exhaust system.
White exhaust smoke
Excessive white smoke from the exhaust is often a sign that coolant is entering and evaporating in the exhaust flow—a typical symptom of a leaking cooler.
Warning lights
Emission-related alerts, including SCR system warnings, can be triggered when the EGR system is not functioning correctly due to a leak.
Engine performance issues
A leaking EGR cooler can affect combustion balance, leading to rough running, reduced power, or inconsistent engine behaviour.
Unusual exhaust deposits
Wet or abnormal residue in the exhaust system may point to coolant contamination, which can damage downstream components if left unresolved.
With the Dinex EGR Cooler Repair kits, Dinex extends its emission expertise further upstream – supporting a more complete, system-based approach to repair, while enabling more resource-efficient maintenance.
All our kits comes complete with all necessary gaskets and mounting hardware, making it easy to replace these critical sealing components and make it a long lasting repair.
When needed, the EGR Cooler's Flow Valves should be replaced at the same time as the radiator is replaced. In those cases we have of course also these available for separate ordering.
See the full range of EGR Cooler Repair Kits from Dinex, and explore additional resources below.
