Although combustion is essential in most energy generation processes, it is one of the major causes of air pollution. Spiral fin exhaust pipes were designed to study the effect of cooling the recirculated exhaust gases (EGR) of Diesel engines on the chemical composition of the exhaust gases and the reduction in the percentages of pollutant emissions. The gases examined in this study were oxides of nitrogen (NOx), carbon dioxide (CO2) and carbon monoxide (CO). In addition, O-2 concentration in the exhaust was measured. The two designs adopted in this study were exhaust pipes with solid and hollow fins around them. The first type uses air flow around the fins to cool the exhaust gases. The second type consists of hollow fins around the exhaust pipe to allow cooling water to flow in the hollow passage. Different combinations and arrangements of the solid and hollow fins exhaust pipes were used. It was found that decreasing the temperature of the EGR resulted in reductions in the oxides of nitrogen (NOx) and carbon dioxide (CO2) but increased the carbon monoxide (CO) in the exhaust gases. In addition, the oxygen (O-2) concentration in the exhaust was decreased. As a general trend, the percentages of reduction in the NOx gas concentrations were lower than the percentages of increase in the CO emissions as a result of cooling the EGR of a Diesel engine by a heat exchanger. Using water as a cooling medium decreased the exhaust gases temperature and the amount of pollutants more than did air as a cooling medium. In a separate series of tests, increasing the cooled EGR ratios decreased the exhaust NOx but increased the particulate matter concentrations in the exhaust gases. (C) 2003 Elsevier Ltd. All rights reserved.