Did I read here that the round(early) EGR cooler had a failure rate which was far less than the square EGR cooler?
If not, is it true or do they both fail at about the same rate?
Would like to know as I have the round one and if it is better then maybe no EGR delete needed.
Thanks.

 

my original round 03 cooler has 423000km on it.

 

I just replaced oil cooler and there was nothing wrong with my egr cooler they are fullproof. they 03s have stianless tubes welded in, there faillure rate is hardly any. i did weld mine up though. O well messed up perfectly good cooler.

 

If you monitor your ECT and EOT and you have more than a 15 degree difference you may have a plugged engine oil cooler. The failures are caused by the engine oil cooler plugging and reducing the coolant flow to the EGR cooler which then overheats and fails.

 

I concur with the previous posts. Mine was the square one, and when my engine oil cooler was failing (high variance between EOT & ECT) I had it replaced with the bulletproof EGR cooler. It is shame that it was not diagnosed properly when my EGR cooler failed the first time when the truck was still under warranty. It would have saved me the cost of a HPOP and Oil cooler.

 

First of all, they are not interchangable, so it doesnt matter. Like posted above check your delta to see if you have a problem.
The round coolers are a better design.

 

I have a 2003 which has the round EGR cooler. I did a lot of research, speaking with tech's both in local dealerships and the forums. The overwhelming consensus is that the 2003 coolers are not a little bit better, but leaps and bounds better than the square design. The bottom line is if you have a round cooler, there is really no need to remove it to prevent a problem. Many of the tech's I spoke with said that they NEVER saw a 2003 EGR cooler fail, some saw less than 3. This doesn't mean that they can't fail it simply means that with the round EGR cooler it's unlikely that you will have a failure.

The argument is just delete it anyway then you are 100% assured that it wont fail, which of course is correct. Ultimately it's your decision, but when making the decision keep in mind that emissions testing will only get tougher and the EGR system is federally mandated equipment. Additionally the engine was designed around the EGR system removing it will alter the design, some think for the better some think for the worse. I kept mine more or less that I wouldn't have any hassle with emissions testing in the future.

This in NO WAY means that it's okay to run with a plugged up oil cooler though. If your coolant / oil temperatures are not within 15 degrees, you need to replace that oil cooler regardless of the type ore even presence of your EGR cooler. Remember oil runs this engine, not just lubricates it so anything that is oil related is so critical to keep within the design tolerances.

It's my understanding that you can easily fit a 2003 round EGR cooler into your later models by changing the EGR cooler and up-pipe. I don't believe that the intake needs to be changed but I have never done this so I really don't know.

 

Correct they are not interchangeable unless you do the exhaust branch pipe,EGR cooler, and the intake manifold. I speak from having tried on my own vehicle. All I wanted was the newer Open back intake, but that ended up being a can of worms.

 

Just want to say thanks for everyones input. Verfy helpful.

'HAPPY NEW YEAR' to all.

 

the round design of 03 and the square design on 06 have the same part number stamped on the and they look very similar ,i do not see why they will not work,the may have some different designs too?

 

They won't interchange as lenzhotrod said previously and for the reasons he listed.