Restricted or Cracked Charge Air Cooler
Check as follows:
To avoid engine damage, follow the installation instructions provided with the air-to-air charge air cooler test kit.
- Attach an air-to-air charge air cooler test kit ( J–41473); refer to OEM guidelines.
- Disconnect the air inlet hose from the outlet side of the turbocharger compressor housing; refer to appropriate service manual, air intake system chapter.
- Attach the air-to-air cooler test kit adaptor plug to fit into the hose at the compressor connector; refer to OEM guidelines.
- Attach an air pressure hose to the air chuck at the regulator and gradually pressurize the air inlet system to a pressure of 177 kPa (25 psi).
- Apply a water and soap solution to each hose connection, across the face of the charge air cooler.
- Apply a water and soap solution to the air intake manifold and cylinder head mating surface area.
- Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks.
- If air leaks are present around the joints, replace the charge air cooler; refer to OEM guidelines.
- If any leaks are present around the air intake manifold, repair the air intake manifold; refer to appropriate service manual, air intake system chapter.
- If no leaks are present, check for faulty exhaust system; refer to "6.5 Leaky Exhaust System" .
- To determine if the replaced charge air cooler and air intake manifold resolved the excessive exhaust smoke condition, start and run the engine.
- Run the engine at idle with a no-load for approximately five minutes, allowing the engine coolant to reach normal operating range.
- Visually inspect exhaust for excessive smoke.
- If the engine exhaust emission appears normal, no further troubleshooting is required. Shut down the engine.
- If the engine exhaust emission is excessively black or gray, shut down the engine. Check the faulty exhaust system; refer to "6.5 Leaky Exhaust System" .
|EPA07 DD15 Troubleshooting Guide - DDC-SVC-MAN-0029|
|Generated on 10-13-2008|