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Discussion Starter #1
Hey guys today I found an exhaust leak between the EGR muffler and EGR valve

I have pretty much no experience with EGR but even this don't look right to me

445396
445397
 

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Not quite sure what you're trying to find out but just going on my limited knowledge and what I see in your photos.

So what you have there is the EGR cooler.There's an outer jacket that is fed with engine coolant which is those two pipes that are welded closed that I find somewhat hilarious at what extremes people will go to to botch things up.

These assemblies have been know to fracture in the jacket which will then cause a loss of coolant and feed that into the intake.

The other item, not sure if that is part of the internals or gasket that has been made up in an attempt to block off the EGR process. It's not OEM, the gasket between the EGR valve and this cooler is a flat stainless steel gasket, looks nothing like this.

That cooler is also on the D4EA motors as well in Kia and Hyundai.
 

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Discussion Starter #4
I was surprised to see it welded up, the gasket came out between the cooler the EGR valve. Also if u look close was a bolt snapped in thst housing.
 
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