[cm335d]

Has anyone attempted repairing a cracked EGR Cooler? Mine looks like it may have a small crack inbetween the folds in the bellows, as I see some black soot in this area (will try to take a pic soon and post).
If anyone has one for sale cheap that is in good condition, I'd love to hear from you.
I was thinking about sourcing a replacement bellows and then cutting off the old one and rewilding a new one on. If I'm going that route, I'd sure like to have the bellows on hand before I take my car apart since its my daily driver. Thought and suggestions appreciated.

[9mmkungfu]

Originally Posted by cm335d

Has anyone attempted repairing a cracked EGR Cooler? Mine looks like it may have a small crack inbetween the folds in the bellows, as I see some black soot in this area (will try to take a pic soon and post).
If anyone has one for sale cheap that is in good condition, I'd love to hear from you.
I was thinking about sourcing a replacement bellows and then cutting off the old one and rewilding a new one on. If I'm going that route, I'd sure like to have the bellows on hand before I take my car apart since its my daily driver. Thought and suggestions appreciated.

Mine is still installed but not in use. If I can get it removed soon ish, you're welcome to it.

[cm335d]

Originally Posted by 9mmkungfu

Mine is still installed but not in use. If I can get it removed soon ish, you're welcome to it.

That would be super cool. Please let me know, thanks very much!

[Yozh]

There are lots kicking around. I have one if you want.

[cm335d]

Originally Posted by Yozh

There are lots kicking around. I have one if you want.

Yozh, that would be cool. Are you in the Los Angeles area by chance? If not, can I paypal you some shipping money?
I just took a picture of where I think the EGR cooler is leaking from, circled in red. It's not a huge leak, just enough to smell. Car still runs as normal.

Pic: https://photos.app.goo.gl/87ttrbP8P6ZTemjLA

[cm335d]

Got a used one coming from one of the forum members! Thanks guys, it sure it helpful to have a community of owners that help each other out!

[Thecastle]

Originally Posted by cm335d

Has anyone attempted repairing a cracked EGR Cooler? Mine looks like it may have a small crack inbetween the folds in the bellows, as I see some black soot in this area (will try to take a pic soon and post).
If anyone has one for sale cheap that is in good condition, I'd love to hear from you.
I was thinking about sourcing a replacement bellows and then cutting off the old one and rewilding a new one on. If I'm going that route, I'd sure like to have the bellows on hand before I take my car apart since its my daily driver. Thought and suggestions appreciated.

Ive had 3 EGR cooler break there (3x replaced for broken accordion pipe, 1x replaced for leaking coolant) I eventually deleted the cooler and resolved the issue. There is a recall or SIB on the bolts that hold the cooler in place that can cause the accordion pipe to crack.

To my knowledge no one repairs these. There are a lot of used ones, ebay ones, a car-parts ones from wrecked cars.

[DieselOG]

What about a little dab of jb weld? Just a thought. I've fixed multiple cracked marine blocks with jb weld, it holds up just fine at high temps.

[cm335d]

Originally Posted by DieselOG

What about a little dab of jb weld? Just a thought. I've fixed multiple cracked marine blocks with jb weld, it holds up just fine at high temps.

I actually thought about doing that with some of the high-temp stuff that JB Weld makes for this exact type of scenario. My thoughts were that it would be a temporary fix, likely to crack again over time. I'm going to replace mine with a known good unit and then attempt to weld repair my old one so that I have a back up.

[adriang]

Hello anyone have an EGR cooler sitting around? I need one please

[Yozh]

I’ve got one. PM me.

[remlemasi]

Originally Posted by cm335d

I actually thought about doing that with some of the high-temp stuff that JB Weld makes for this exact type of scenario. My thoughts were that it would be a temporary fix, likely to crack again over time. I'm going to replace mine with a known good unit and then attempt to weld repair my old one so that I have a back up.

Reinstalled the EGR cooler last weekend so I can go get the car smogged (California) and I end up with diesel fumes in the cabin. Thought it was the CCV hose at first so I ordered a replacement from Andrew. Looks like it was OK, although cracks were starting to form in the accordion section so I replaced it anyway.

While replacing the CCV hose, I noticed a ring of black soot around one of the accordion folds of the EGR cooler, exactly what's shown in this thread. Sure, enough CCV hose was not the culprit and the leak remains and is smell very strong in the immediate area. Must be the ten times I've removed and reinstalled the cooler.

I was thinking of doing JB weld as well. Since this is coming off as soon as I pass smog testing, maybe just slathering it on the whole accordion section and then wrapping it with some hi-temp resistant tape to prevent leaks in the future. Thoughts?

In parallel, any non-California folks have a spare EGR cooler laying around willing to donate?

[cm335d]

After seeing how bad the crack was when I originally took mine off, I'm pretty certain that no amount of JB weld would hold for any length of time. If you could find a replacement bellows to fit and clamp on, that would be the way to go, or, since you're going to remove the assembly later anyhow, you could cut the bellows out and replace it with a piece of tubing and a clamp on each side? It wouldn't last because you'd be taking out the flex that the bellows provides, but maybe it would be the trick to get you by for now? Just a thought.

[Soonerbilly]

I got a couple if needed. PM me. Few bucks and shipping.

[Soonerbilly]

I ALso have a Lowish miles DPF if anyone needs one ( 50k miles ).

[PerfectAce]

[remlemasi]

Update, just a half-hour ago, I'm driving around and I hear a clackity-clack when I apply any throttle at all and power is wayyy down. Sure enough a limp mode pops up on the dash and Carly shows code 4530.

Haven't had the time to tear down into it yet, but I'm guessing the small crack has blown wide open, resulting in the loose accordion/bellows banging around (noise) and no boost pressure since all the exhaust is leaking out (limp mode). You all concur?

Originally Posted by cm335d

After seeing how bad the crack was when I originally took mine off, I'm pretty certain that no amount of JB weld would hold for any length of time. If you could find a replacement bellows to fit and clamp on, that would be the way to go, or, since you're going to remove the assembly later anyhow, you could cut the bellows out and replace it with a piece of tubing and a clamp on each side? It wouldn't last because you'd be taking out the flex that the bellows provides, but maybe it would be the trick to get you by for now? Just a thought.

Good idea on the tubing. Maybe ensure no full throttle applications so the tubing doesn't blow out either...

Originally Posted by Soonerbilly

I got a couple if needed. PM me. Few bucks and shipping.

PM incoming

[cm335d]

My car never went into limp mode and my bellows was cracked damn near 3/4 of the diameter. I never went WOT though because I knew it was leaking and was just babying it until I got my replacement. I don’t think you would loose much boost pressure, but have no way to verify that.

[Dlude]

Hi,

My egr is cracked as well. Let me know if anyone is looking to get rid of one. Thanks!