Unplugged EGR valve causing cooler failure? - Ford Powerstroke Diesel Forum
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Old 10-14-2009, 06:59 AM
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Unplugged EGR valve causing cooler failure?

I read on here that unplugging the EGR valve will trap the hot exhaust gas inside the cooler and cause it to fail sooner, I have had mine unplugged since 42,000 miles and now have 76,000 miles with no problems yet,

I can't see how the gas would just sit it the cooler, it would still circulate and find it's way out the exhaust just not go through the intake with the valve unplugged.....is this right?
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Old 10-14-2009, 07:48 AM
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Yeah, that is not true. The cracking of the fins inside the cooler was caused by heat cycling, when the valve would open the metal got hot it would expand, then when you close the valve it would cool (in relation) and contract, so it was constantly being cycled in tension and compression, thus it would eventually separate allowing coolant into the cooler. The cooler would be under a lot more stress if the valve was open because conduction heat transfer is directly related to mass flow rate of exhaust gas over the cooler. When the EGR valve is closed it is not doing much cooling because there is no flow rate, put your hand under a small drip of boiling water or put your hand in the whole pot of boiling water, what has more heat transfer to your hand. Air in this case is acting in the same way, if there is no air passing through the cooler then it is just a little air trapped inside, circulating randomly, with not much conduction to the coolant. If you open that valve then the hot gas will rapidly flow through causing a lot of heat transfer into the coolant. These sharp increases and decreases in temp cause the stress fractures of the fins.
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Old 10-14-2009, 12:14 PM
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Thanks, so running the valve unplugged won't hurt anything? actually may help by not causing temperature extremes?
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