Series 60 DDEC VI Troubleshooting – Section 12.7 Restricted or Cracked Charge Air Cooler or Leaking Intake Manifold

Section 12.7
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 steps:‪

1. Attach air-to-air charge air cooler test kit, J-41473; 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 205 kPa (30 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 charge air cooler leaks are present around the joints, replace the charge air cooler; refer to "12.7.1 Charge Air Cooler Replacement" .
   2. If the intake manifold leaks, repair intake manifold; refer to "12.7.2 Air Intake Manifold Repair" .
   3. If neither charge air cooler nor intake manifold leaked, check the exhaust system; refer to "12.8 Faulty Exhaust System" .

Section 12.7.1
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 "12.7.2.1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold" .
3. If the intake manifold leaks, repair intake manifold; refer to "12.7.2 Air Intake Manifold Repair" .

Section 12.7.2
Air Intake Manifold Repair

Perform the following steps to repair the air intake manifold: ‪

1. Remove the air intake manifold; refer to Series 60 Service manual (6SE2007), Air system chapter.
2. Inspect the air intake manifold; refer to Series 60 Service manual (6SE2007), Air system chapter.
3. Install the air intake manifold; refer to Series 60 Service manual (6SE2007), Air system chapter.
4. Verify repair of the intake manifold; refer to "12.7.2.1 Test the Engine with Replaced Charge Air Cooler and Air Intake Manifold" .

Section 12.7.2.1
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 steps:‪

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

ENGINE EXHAUST ‪
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.‪

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 down the engine.
   2. If lack of power occurred during the test drive, shut down the engine. Check the exhaust system; refer to "12.8 Faulty Exhaust System" .