All About Cummins EGR Coolers

All About Cummins EGR Coolers

For several years, the Cummins Engine has established its place. It is now renowned as one of the most influential and dependable engine platforms, serving its purpose for all kinds of light, medium, and heavy-duty trucks. Studies have proven that around 75% of all Ram 2500/3500 pickup truck owners have opted for the Cummins Turbo Diesel engine. 

Introduced in 2019, the 1000 lb-ft of torque variant seemed to facilitate buyers in concentrating more on the reliability and status of the engine. This focus was in contrast to the usual instances of the buyers fixating their attention on the interiors, which, in this case, were comparatively inferior to other diesel trucks in their sector. Irrespective of the critical but communal comments like the Ram trucks falling apart around the Cummins engine, the Cummins engine’s repute has corroborated itself as a vital decisive element for all those seeking a diesel engine pickup.

In 2008, individuals who chose the Cummins engine for their Ram truck made an update in their choice itself. They embraced the option of the 6.7L variant of the engine departing from the outdated 5.9L version prevalent in the market since 1989. The 6.7L appeared to be superior to the 5.9L in practically every manner. Nevertheless, Cummins had to add an EGR (Exhaust Gas Recirculation) system to ensure that they followed the strict emission control mandates. 

This addition preordained that the failures of the EGR cooler, which were present on the Power Stroke and Duramax variations in the preceding years, were bound to emerge on the Cummins engine. Even though these malfunctions were not as common for Cummins as was for the 6.0L Power Stroke engine, the error existed. It could and would have led to more catastrophic damages to the engine.

In the instance of the failure of an EGR cooler, it will, in customary cases, permit the engine coolant to enter the cylinders. It would result in the materialization and emergence of white steam or smoke from the exhaust present in the engine. However, the outcome of this observation could lead to a reverse consequence as people would believe that a cylinder head or head gasket failure has ensued. It is primarily because, without the installment of an EGR system, the symptoms usually depict the latter. 

Owing to the foreign nature of the EGR cooler system and the confusing indications of the issue, the Cummins owners and technicians made a dreadful misdiagnosis of the underlying dilemma. Misled by the symptoms, the mechanics put their efforts behind repair work by replacing the head gasket. However, it all resulted in vain as the source of the problem lay elsewhere. This entire ordeal turned out to be a burdensome and enormous blunder. It was the case for the professionals who developed the engine and the owners of the vehicles having the engine. 

With the onset of the rumors that EGR coolers brought with it several problems and that once it failed, it could result in severe engine damage, the tide changed. The customers and the facilities, offering repair services to these engines, commenced seeking appropriate, enhanced, and upgraded alternatives for safer and longer use.  

The factory EGR coolers generally apply the system of a tube and fin style for the heat exchanger. Its internal segment resembles a radiator. The primary concern for these kinds is that once the EGR cooler starts heating and cooling, the metal inside also begins expanding and contracting by responding to the heat received. This constant expansion and contraction for extended periods put significant strain on the inflexible internal mechanism, resulting in cracks in the heat exchanger. When the internal failure transpires, the engine coolant can enter the exhaust system or the cylinders. It can lead to various engine malfunctions of a more critical scale, such as head gasket breakdown. These types of failures are commonplace among all factory EGR coolers. 

However, its solution may not come so soon. To date, it does not seem as if the OEMs are concerned with or interested in solving this problem. Several allegations from various sources have it that the OEs acquire better income and profit through selling replacement parts than what they do by marketing the trucks. If that is true, then it is not such a big mystery why they are so indifferent to the root of the problem. 

There are a few substitute options for the factory EGR coolers available in the market. Nevertheless, various similarities lie in their design compared to the factory unit. On account of this, one cannot claim them to be upgraded versions as they may exhibit failure in an analogous fashion. 

Fortuitously, a developed and upgraded version exists that applies a new way of the thought process behind the working of heat exchangers and can resolve the prevailing setback.

Located in Mesa in Arizona, Bullet Proof Diesel developed and patented a heat exchanger technology, naming it H-Core. They produce all BulletProof EGR Coolers at their manufacturing plant in Mesa and offer their improved versions for almost all types of the Cummins engine. But how exactly does H-Core help solve the existing problem?

H-Core finds its application in the upgrading of the EGR coolers to make them more reliable. Its mechanism includes the use of twisted sets of tubes instead of the conventional straight or rigid ones. It grants the EGR coolers the flexibility that was previously missing in them. It also helps reduce the stress on the bulkheads and seams to a great extent. The tubes act similar to springs in that they can expand and contract without exerting any unwarranted stress or strain on the heat exchanger assembly. 

This type of construction permits the tubes to be stacked close together. Therefore, it allows for more tubing and a colder EGR gas than what would have been the case with traditional straight versions. As such, the BulletProof EGR Cooler came as a blessing to the owners of the Cummins engine. People claimed it to be so as the necessity to install a factory EGR cooler, on the failure of the cooler, disappeared. As such, an influx of the proactive installment of the cooler followed its release to the market.

In the long run and ultimately, Cummins has proven itself to be a reliable, steadfast, and long-lasting engine platform when considering and evaluating the overall performance. It leaves very little room for improvement, except for the case of the factory EGR cooler for apparent reasons. 

If you wish to go over the entire arrangement and functioning of the upgraded and improved EGR Cooler launched by Bullet Proof Diesel, H-Core, visit

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