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EGR Coolers

Roadwarrior's catalogue is always growing! Let us know which part number you are looking for and we will find your cross and get back to you. If your part is not currently in production, we can consider building it for you. 

You’re in the middle of a job when your semitruck starts flashing up a fault code. Your DTC scan tool says you have a faulty EGR cooler, and your mechanic says you need a new part! Should you accept the high price and potentially long wait for a new OEM part or risk an unknown aftermarket seller? But then you realize there’s a third option! You order a replacement Roadwarrior EGR cooler either online or through your dealer. Coming from a well-known aftermarket manufacturer with 13 North American warehouses, your new EGR cooler arrives much faster and costs much less than expected! You replace the part and get your semitruck’s EGR system up and running in no time.


Which Replacement EGR Coolers Does Roadwarrior Stock?

Our catalogue includes a Roadwarrior replacement (EGR-00CU-01) for the Cummins ISX EGR cooler, which is compatible with 2010-2017 Cummins ISX engines. EGR-00CU-01 is a direct-fit replacement for 3rd generation Cummins part numbers 3688606, 3689282 and 3689565. We also offer a replacement for Detroit DD15 EGR cooler EA4721400475, which has the Roadwarrior part number EGR-00DE-01. This plug-and play cooler is suitable for post-2010 Detroit DD15 engines. We’re currently developing aftermarket EGR coolers for several other OEMs, so let our sales team know if you don’t see your part and we’ll look into adding it.


What is an EGR Cooler and Why Do You Need One?

An EGR cooler is part of the exhaust gas recirculation (EGR) system. Hot exhaust gas leaves the engine through the exhaust manifold, travels to the EGR cooler and is cooled down before returning to the combustion chamber. However, if the EGR cooler fails, the heat of the returning exhaust can jam open the EGR valve, flooding the engine with exhaust. Diesel combustion chambers need exact temperatures to run smoothly, so this can cause misaligned compression, engine knock and piston damage. You can avoid these problems by replacing or repairing faulty EGR coolers and searching for underlying issues like blocked coolant lines!


Why are Roadwarrior EGR Coolers a Good Investment?

When it comes to the aftertreatment industry, we go out of our way to be a brand you can trust! Our ties to DCL International give us access to superior materials and the latest emissions control research, and our engineers use this to create products you can rely on! These benefits have helped us build the largest catalogue of aftermarket aftertreatment parts in the industry, and our selection is always growing.

In recent years, we’ve seen the problems semitruck drivers have had with EGR coolers and the difficulty of replacing them. We realized we could help OTR drivers by tackling these issues and producing reliable aftermarket EGR coolers! In the rare instance that one of our parts is faulty, our industry-leading record of honoring warranty claims means we can send a replacement part out in no time.

Major Benefits of EGR!

  • Keep your truck emissions compliant!

Meet emissions regulations, reduce regens and take the pressure off your aftertreatment system by reducing the soot generated by idling.

  • Improve your fuel economy!

Cut down fuel consumption by re-burning the soot-rich exhaust from low-duty cycles like idling and driving in heavy traffic.

  • Protect your Engine!

The chilled exhaust from the EGR cooler helps control combustion temperatures. This is important because over-hot combustion can jam your EGR valve and damage the piston and crankshaft in your combustion chamber.

  • Reduce Your Regens!

The EGR reduces soot build-up on the DPF by re-burning soot-heavy exhaust from the EGR cooler before it reaches the DPF. This means fewer inconvenient forced regens, because DPF regens are the truck’s way of removing accumulated soot, ash, and dirt.


Can EGR reduce engine power or fuel efficiency?

A properly functioning EGR won’t noticeably impact engine power and can improve fuel efficiency! The EGR valve is closed when you start the engine, accelerate, hit high speeds, climb steep hills, and pull extra-heavy loads. This means the cooled exhaust doesn’t enter the engine, it gets the pure oxygen. This allows the engine to reach higher combustion temperatures, burn more fuel and produce the extra power needed. The EGR valve begins to open in settings that require less power and generate excess soot, like driving in traffic and idling. This reduces combustion temperatures, saves fuel, and protects your aftertreatment system and engine from soot build-up!


Why do EGR coolers fail?

Soot from excessive idling can clog the lines, stopping the exhaust reaching the EGR cooler, and sometimes creating enough pressure to split the lines. The exhaust lines can also become clogged when oil leaks into the combustion chamber, forming an oil and soot sludge that escapes through the exhaust manifold!

Another common cause of EGR cooler failure is blocked oil coolant lines stopping coolant reaching the tank! Without coolant, the EGR cooler can’t function and hot gas returns to the engine, disrupting combustion and reducing fuel economy! The heat of the gas can also jam the EGR valve open, letting uncontrolled amounts of exhaust into the engine.


Are Roadwarrior EGR coolers covered by a warranty?

Yes, Roadwarrior products come with a hassle-free warranty that makes them easy to return if you have any problems! Our parts also come with permanent and easy-to-identify serial numbers. This allows us to have an industry-leading record of honoring claims!


Can EGR coolers handle the cold?

EGR coolers are usually located high up in the cooling system, and the exhaust lines pass through the coolant tank, so the cold shouldn’t be an issue. However, pressure build-up from blocked coolant lines can crack the EGR cooler or split the lines. If this happens, coolant may escape into the exhaust as boiling steam and leave the truck as white exhaust smoke!


Why is EGR delete a bad idea?

EGR is an emissions-control system that returns exhaust gas and partially burnt fuel to the engine at low speeds and during idle. This lowers soot levels in the exhaust, protecting the aftertreatment system and reducing regens! EGR delete means removing a system your engine relies on! Your semitruck also uses the cooled exhaust from the EGR cooler to control combustion temperatures. This stops the engine running too hot, improves fuel efficiency, and reduces the risk of engine knock and misaligned compression! As EGR is often a legal requirement, deleting yours can also lead to failed emissions tests, heavy fines and even losing your operating license!


Better Coating, Better Performance.

Roadwarrior is the only manufacturer to use Metalcor® catalyst technology across its entire range of Diesel Oxidation Catalysts (DOCs) and Selective Catalytic Reduction catalysts (SCRs). Metalcor® catalysts feature high activity catalyst coatings fused to thinner, stronger, catalyst substrates to guarantee maximum performance under the harshest conditions.

Metalcor® catalyst coatings are designed and produced in our own labs. We then inspect each unit to ensure you get more fuel efficiency, lower consumption of DEF, and long term performance from your heavy duty engine!


Roadwarrior Has You Covered!

All Roadwarrior emissions parts carry a full value 12 month warranty.

LightningVolt lithium batteries carry a full value 30 month warranty.

To make the process hassle-free, our parts have a metal nameplate with the serial number, so even after 500,000 miles of service, it’s still easy to identify. This avoids the common problem of serial numbers printed on stickers that burn off after the first start-up, making them impossible to return. Our failsafe system allows us to work in your interests, honouring claims for on-road and off-road replacements, and giving you peace of mind.

And since Roadwarrior parts are designed to meet or exceed OEM specifications, you can rest easy knowing our direct fit parts will take the problems out of your aftertreatment without interfering with your OEM warranty.

Next Day Is Nice, Same Day is Better!​

A faulty emissions control system can cost you thousands in wasted man-hours as your heavy equipment sits in the shop awaiting a new part. Whether it’s a truck behind on orders, a bus that can’t take passengers, or heavy machinery delaying construction deadlines, Roadwarrior can get you moving again! 

Roadwarrior has twelve warehouses across the U.S.A. and Canada, which can deliver the most popular aftertreatment parts in 1-2 days. With over 1,000 DPFs, DOCs and SCRs on offer, Roadwarrior offers the largest aftertreatment catalogue.

*LightningVolt lithium batteries ship directly from Roadwarrior in Ontario, to ALL 50 states, including Alaska and Hawaii within 2-4 days.