Series 60 DDEC VI Troubleshooting – Section 8.3 Restricted or Cracked Charge Air Cooler

Section 8.3
Restricted or Cracked Charge Air Cooler

To determine if a charge air cooler is causing excessive exhaust smoke, perform the following:‪

1. Attach a WK93 air-to-air charge air cooler test kit; refer to OEM guidelines.
2. Disconnect the air inlet hose from the outlet side of the turbocharger compressor housing; refer to appropriate service manual, air intake system chapter.
3. Attach the air-to-air cooler test kit adaptor plug to fit into the hose at the compressor connector; refer to OEM guidelines.
4. 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).
5. Apply a water and soap solution to each hose connection, across the face of the charge air cooler.
6. Apply a water and soap solution to the air intake manifold and cylinder head mating surface area.
7. Visually inspect all joints for air leaks and all charge air cooler welded surfaces for stress cracks.
   1. If air leaks are present around the joints, replace the charge air cooler; refer to "8.3.1 Charge Air Cooler Replacement" .
   2. If any leaks are present around the air intake manifold, repair the air intake manifold; refer to "8.3.2 Air Intake Manifold Repair" .
   3. If no leaks are present, check for faulty exhaust system; refer to "8.4 Faulty Exhaust System" .

Section 8.3.1
Charge Air Cooler Replacement

Perform the following steps to replace the charge air cooler:‪

1. Replace the charge air cooler, refer to OEM guidelines.
2. Verify replacement of the charge air cooler; refer to "8.3.2.1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold" .

Section 8.3.2
Air Intake Manifold Repair

Perform the following steps to repair the air intake manifold:‪

1. Remove the air intake manifold; refer to appropriate service manual, air intake system chapter.
2. Inspect the air intake manifold; refer to appropriate service manual, air intake system chapter.
3. Install the air intake manifold; refer to appropriate service manual, air intake system chapter.
4. Verify repair of the air intake manifold; refer to "8.3.2.1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold" .

Section 8.3.2.1
Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold

To determine if the replaced charge air cooler and air intake manifold resolved the excessive exhaust smoke condition, perform the following:‪

1. Start and run the engine.
2. Run the engine at idle with a no-load for approximately 5 minutes, allowing the engine coolant to reach normal operating range.
3. Visually inspect exhaust for excessive smoke.
   1. If the engine exhaust emission appears normal, no further troubleshooting is required. Shut down the engine.
   2. If the engine exhaust emission is excessively black or gray, shut down the engine. Check the faulty exhaust system; refer to "8.4 Faulty Exhaust System" .