Increasingly stringent exhaust emission regulations, which are expected to come into force within the next couple of years will require substantial reductions of NOx as well as particulate emissions. To meet these future emission standards, the application of new technologies will be indispensable, especially in view of maintaining or even improving the thermal efficiency of LD, MD and HD diesel engines . Exhaust Gas Recirculation (EGR) is a proven method to reduce NOx emissions. This paper outlines the development and layout of a high load EGR system by means of 3D-CFD and thermodynamic cycle simulation. The analytical approach is presented and simulation results are compared to those achieved on the test bed.