Series 50 – Section 25.5 Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold

Section 25.5
Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold

To determine if a restricted or cracked charge air cooler or leaking manifold is causing lack of power, perform the following:‪

1. Test the charge air cooler; refer to "21.3 Restricted or Cracked Charge Air Cooler" .
2. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks.
   1. If charge air cooler leaks are present around the joints, replace the charge air cooler; refer to "25.5.1 Charge Air Cooler Replacement" .
   2. If the intake manifold leaks, repair intake manifold; refer to "25.5.2 Air Intake Manifold Repair" .
   3. If neither charge air cooler nor intake manifold leaked, check the exhaust system; refer to "25.6 Faulty Exhaust System" .

Section 25.5.1
Charge Air Cooler Replacement

Perform the following steps to replace the charge air cooler:‪

1. Remove and replace the charge air cooler; refer to OEM guidelines.
2. If the intake manifold doesn't leak, verify replacement of the charge air cooler; refer to "25.5.2.1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold" .
3. If the intake manifold leaks, repair intake manifold; refer to "25.5.2 Air Intake Manifold Repair" .

Section 25.5.2
Air Intake Manifold Repair

Perform the following steps to repair the air intake manifold: ‪

1. Remove the air intake manifold; refer to "6.3.4 Cleaning and Removal of Intake Manifold" .
2. Inspect the air intake manifold; refer to "6.3.4.1 Inspection of Intake Manifold" .
3. Install the air intake manifold; refer to "6.3.5 Installation of Intake Manifold" .
4. Verify repair of the intake manifold; refer to "25.5.2.1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold" .

Section 25.5.2.1
Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold

To determine if the repairs resolved the lack of power condition, perform the following:‪

1. Start and run the engine.
2. Test drive the vehicle to ensure lack of power has been resolved.
   1. If no lack of power occurred during the test drive, no further troubleshooting is required. Shut the engine down.
   2. If lack of power occurred during the test drive, shut the engine down. Check the exhaust system; refer to "25.6 Faulty Exhaust System" .