Methods and systems are provided for an EGR system including an EGR cooler module directly mounted to a cylinder head. In one example, the EGR cooler module includes an EGR inlet port, an EGR outlet port, a coolant inlet port, and a coolant outlet port all arranged parallel with each other and directly mounted to a first side of a cylinder head to interface with passages internal to the cylinder head. In another example, the EGR cool module includes an EGR inlet port and a coolant inlet port parallel to each other and directly mounted to a first side of a cylinder head to interface with passages internal to the cylinder head, while also including an EGR outlet port and a coolant outlet port to interface with passages external to the cylinder head.

Methods and systems are provided for exhaust flow in an engine system including a split-exhaust manifold for expediting exhaust catalyst light-off and engine warm-up while reducing condensation in the engine system. In one example, a method may include, before exhaust catalyst light-off, flowing all or more exhaust gases, via a first exhaust valve and a first exhaust manifold, to an exhaust catalyst by passing a heat exchanger. Further, after light-off but before engine coolant warms up to a threshold temperature, all or more exhaust may be delivered to the heat exchanger, via a second exhaust valve and a second different manifold, prior to flowing to the exhaust catalyst; and exhaust gas recirculation may not be provided until the coolant reaches the threshold temperature to reduce condensation.

Methods and systems are provided for exhaust flow in an engine system including a split-exhaust manifold for expediting exhaust catalyst light-off and engine warm-up while reducing condensation in the engine system. In one example, a method may include, before exhaust catalyst light-off, flowing all or more exhaust gases, via a first exhaust valve and a first exhaust manifold, to an exhaust catalyst by passing a heat exchanger. Further, after light-off but before engine coolant warms up to a threshold temperature, all or more exhaust may be delivered to the heat exchanger, via a second exhaust valve and a second different manifold, prior to flowing to the exhaust catalyst; and exhaust gas recirculation may not be provided until the coolant reaches the threshold temperature to reduce condensation.

A system for recycling exhaust heat from an internal combustion engine is based on a recycling type of circulating a working fluid using the exhaust heat from the internal combustion engine. The system may include an EGR line configured to circulate a portion of exhaust gas generated from the internal combustion engine to an intake side, a working fluid circulation line configured to rotate a turbine with a working fluid vaporized by heat transferred from the EGR line, and an EGR side heat exchange unit configured to thermally connect the EGR line to the working fluid circulation line to cool an EGR gas by transferring heat from the EGR gas to the working fluid.

A system for recycling exhaust heat from an internal combustion engine is based on a recycling type of circulating a working fluid using the exhaust heat from the internal combustion engine. The system may include an EGR line configured to circulate a portion of exhaust gas generated from the internal combustion engine to an intake side, a working fluid circulation line configured to rotate a turbine with a working fluid vaporized by heat transferred from the EGR line, and an EGR side heat exchange unit configured to thermally connect the EGR line to the working fluid circulation line to cool an EGR gas by transferring heat from the EGR gas to the working fluid.

An exhaust gas recirculation heat exchanger assembly that includes a tube, a fin structure, and a clip. The tube has first and second walls extending between a first lateral end and a second lateral end. The fin structure is received in the tube to form a cooling tube assembly. The cooling tube assembly defines a first channel between the first lateral end and a first fin of the fin structure, a second channel between the second lateral end and a second fin of the fin structure disposed opposite the first fin, and a plurality of intermediate channels extending between the first and second channels. The clip is coupled to the cooling tube assembly. The clip has at least one flow impeding portion being configured to impede a fluid flow through at least one of the first channel, the second channel, and one or more of the intermediate channels.

An exhaust gas recirculation heat exchanger assembly that includes a tube, a fin structure, and a clip. The tube has first and second walls extending between a first lateral end and a second lateral end. The fin structure is received in the tube to form a cooling tube assembly. The cooling tube assembly defines a first channel between the first lateral end and a first fin of the fin structure, a second channel between the second lateral end and a second fin of the fin structure disposed opposite the first fin, and a plurality of intermediate channels extending between the first and second channels. The clip is coupled to the cooling tube assembly. The clip has at least one flow impeding portion being configured to impede a fluid flow through at least one of the first channel, the second channel, and one or more of the intermediate channels.

An engine having an integrated heat exchanger includes a cylinder head defining combustion chambers; an intercooler embedded at an intake side in the cylinder head and cooling intake gas by using a coolant; an EGR cooler embedded in the cylinder head and cooling exhaust gas, which is discharged from an exhaust side of the combustion chambers and recirculates to the intake side of the combustion chambers through an EGR passageway formed in the cylinder head; and an EGR distribution tube formed at an upper side in the cylinder head, supplied with the exhaust gas passing through the EGR cooler, and having distribution holes through which the exhaust gas is distributed into intake ports connected with the combustion chambers.

An engine having an integrated heat exchanger includes a cylinder head defining combustion chambers; an intercooler embedded at an intake side in the cylinder head and cooling intake gas by using a coolant; an EGR cooler embedded in the cylinder head and cooling exhaust gas, which is discharged from an exhaust side of the combustion chambers and recirculates to the intake side of the combustion chambers through an EGR passageway formed in the cylinder head; and an EGR distribution tube formed at an upper side in the cylinder head, supplied with the exhaust gas passing through the EGR cooler, and having distribution holes through which the exhaust gas is distributed into intake ports connected with the combustion chambers.

An exhaust gas recirculation (EGR) cooler is provided and includes a plurality of tubes that are spaced apart from each other and a cavity that is disposed on an engine to receive the plurality of tubes. A coolant guide guides a coolant to the plurality of tubes and a cover then closes the cavity. The cavity has an inlet port that communicates with a water jacket of the engine and the cavity receives the coolant from the water jacket of the engine through the inlet port.