Dongfeng LoongGine Engine parts EGR cooler assembly 1207010-E9C00

At the core of this assembly is a high-performance tube-and-fin heat exchanger design, optimized to rapidly cool recirculated exhaust gases (EGR) before they re-enter the engine’s combustion chamber. The cooler features 36 precision-machined aluminum alloy tubes (with a diameter of 8mm) arranged in a dense matrix, maximizing the contact area between hot exhaust gases (up to 650°C) and the engine’s coolant (typically 90-100°C). The external fin structure (with a fin density of 12 fins per inch) enhances heat dissipation by increasing airflow around the tubes. This design achieves a cooling efficiency of over 85%, reducing EGR gas temperature by 400-450°C—critical for minimizing nitrogen oxide (NOₓ) emissions and preventing engine knock. Computational Fluid Dynamics (CFD) simulations and bench tests confirm that the cooler maintains stable cooling performance even under maximum engine load (e.g., heavy hauling or high-speed operation)

Constructed from a combination of high-grade materials, the 1207010-E9C00 EGR cooler assembly is built to withstand the harsh, corrosive environment of recirculated exhaust gases. The heat exchanger tubes and fins are made of 6061-T6 aluminum alloy, which offers excellent thermal conductivity (155 W/m·K) and resistance to corrosion from exhaust byproducts (such as sulfuric acid formed by condensation). The inlet/outlet flanges are crafted from 409 stainless steel, providing superior resistance to high-temperature oxidation and rust. All internal coolant passages are coated with a ceramic anti-corrosion layer, preventing scale buildup and electrochemical corrosion caused by coolant additives. Through 5000+ hours of corrosion testing (including salt-spray and acid exposure), the assembly shows no signs of material degradation, ensuring a service life of over 200,000 kilometers—far exceeding the lifespan of generic EGR coolers

Engineered to prevent both exhaust gas and coolant leaks—critical for maintaining EGR system efficiency and engine safety—the assembly features a multi-layer sealing system. The EGR gas inlet/outlet flanges are equipped with high-temperature resistant graphite gaskets (rated for -200°C to 800°C) that compress uniformly during installation to form an airtight seal. The coolant pipe connections use nitrile rubber O-rings with a shore hardness of 70, ensuring a tight seal against coolant leakage even under thermal expansion. Additionally, all mounting bolts are made of heat-treated alloy steel (grade 10.9) with lock washers, preventing loosening due to engine vibration. The cooler’s shell is welded using TIG (Tungsten Inert Gas) welding technology, with all welds subjected to ultrasonic testing to detect hidden defects. Through pressure testing (1.5MPa for coolant passages and 0.8MPa for exhaust gas passages), the assembly maintains a leak rate of less than 0.01 psi/min, ensuring no cross-contamination between exhaust gases and coolant

The 1207010-E9C00 EGR cooler assembly strictly complies with global emission regulations, including China’s National VI Emission Standard and the European Union’s Euro VI standard. It is certified to reduce NOₓ emissions by up to 70% compared to non-EGR engines, helping Dongfeng LoongGine vehicles meet environmental requirements in both domestic and international markets. Designed for easy maintenance, the assembly features a modular structure that allows technicians to inspect or replace internal components (e.g., gaskets, O-rings) without removing the entire cooler from the engine. The coolant passages are equipped with a removable drain plug, enabling easy flushing to remove scale or debris that could reduce cooling efficiency. Additionally, the assembly comes with a comprehensive installation manual and all required hardware (gaskets, bolts, washers), allowing for quick replacement using standard hand tools. This combination of compliance and maintainability makes the cooler a reliable, cost-effective component for fleet operators and vehicle owners