Ecodiesel; Leaking EGR cooler?

[ZeeJay]

Thanks @ZeeJay !
I'll upload a picture of the EGR cooler removed at about 37,000 miles. Maybe you can comment on its condition? Hopefully it is a case of my bench testing not showing a leak even thought its bad. It would make my spending 1k on the the Bulletproof Diesel HP EGR cooler not so bad. @Sandevino suggested coolant leaking from a vent on the bottom of the coolant expansion bottle. I checked my bottle but it does not have a vent on its bottom. I did wrap a white rag around the hose connection on the bottom of the tank. After driving 300 miles there was a very small coolant stain on the rag indicating a thimble of coolant loss there.

My bad on this one man, I literally thought this was a new post…..somehow missed the whole March part and the pile of comments. Didn’t read all of it but at least it’s handled and that’s good.

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[Madtom]

Thanks @ZeeJay !
I'll upload a picture of the EGR cooler removed at about 37,000 miles. Maybe you can comment on its condition? Hopefully it is a case of my bench testing not showing a leak even thought its bad. It would make my spending 1k on the the Bulletproof Diesel HP EGR cooler not so bad. @Sandevino suggested coolant leaking from a vent on the bottom of the coolant expansion bottle. I checked my bottle but it does not have a vent on its bottom. I did wrap a white rag around the hose connection on the bottom of the tank. After driving 300 miles there was a very small coolant stain on the rag indicating a thimble of coolant loss there.

15 k miles on mine now. Mine just went below the min mark. Not sure where the loss of coolant is coming from. Mine had the the CP4 replacement before it left the factory lot. I am running oil analysis on it and will examine report when it gets back in. On our JLU with the 2.0 engine the coolant tank is black(different material for heat resistance as it sits right above the turbo) and you would never know if you were low on coolant until the light comes on...ask me how I know lol system was over a qt low....... but that was over 60k miles..... so maybe 1oz every 2k miles....... After you installed the BD HD cooler did your evaporation rate go down or did you discover another potential leak point? My understanding is that the plastic materials used in the cooling system has a eventual failure rate (for BMWs it seems to be around the8 yr/100k mile mark.)

 

[Railpoler]

15 k miles on mine now. Mine just went below the min mark. Not sure where the loss of coolant is coming from. Mine had the the CP4 replacement before it left the factory lot. I am running oil analysis on it and will examine report when it gets back in. On our JLU with the 2.0 engine the coolant tank is black(different material for heat resistance as it sits right above the turbo) and you would never know if you were low on coolant until the light comes on...ask me how I know lol system was over a qt low....... but that was over 60k miles..... so maybe 1oz every 2k miles....... After you installed the BD HD cooler did your evaporation rate go down or did you discover another potential leak point? My understanding is that the plastic materials used in the cooling system has a eventual failure rate (for BMWs it seems to be around the8 yr/100k mile mark.)

It seems that I am still loosing a little coolant, but It does seem to be a little slower. Its been about 5,000 miles since I replaced the EGR cooler. Its hard to say exactly, but the coolant level seems to have gone down about half the distance between Max and Min., which might be 4 ounces. I did see a sign of evaporated coolant under the expansion tank. There is a chance its leaking at the connection between the tank and the hose that connects to its underside. About 1,000 miles back I wrapped the connection with a white rag. I have yet to check for coolant stains. I am planning on pulling the EGR diffuser tube again to inspect for the black sticky substance that was collecting where the tube enters the intake manifold. I might do that in another 5000 miles. If its clean or has just dry soot I will feel replacing the EGR cooler with the Bulletproof Diesel EGR cooler was a wise choice.

 

[Madtom]

It seems that I am still loosing a little coolant, but It does seem to be a little slower. Its been about 5,000 miles since I replaced the EGR cooler. Its hard to say exactly, but the coolant level seems to have gone down about half the distance between Max and Min., which might be 4 ounces. I did see a sign of evaporated coolant under the expansion tank. There is a chance its leaking at the connection between the tank and the hose that connects to its underside. About 1,000 miles back I wrapped the connection with a white rag. I have yet to check for coolant stains. I am planning on pulling the EGR diffuser tube again to inspect for the black sticky substance that was collecting where the tube enters the intake manifold. I might do that in another 5000 miles. If its clean or has just dry soot I will feel replacing the EGR cooler with the Bulletproof Diesel EGR cooler was a wise choice.

I haven't pulled any of those connectors loose. I do know that for the o-ring connectors if you pull them apart they often need a new o-ring to maintain the seal. Failure to do this creates an area where coolant will seep out, and dry around the fitting. I looked at all the fittings around nothing was visible but will try the white rag method you described. The system on this engine is a closed loop so evaporation should be minimal.

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