17.5 RESTRICTED OR CRACKED CHARGE AIR COOLER OR LEAKING INTAKE MANIFOLD 17.5 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 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 207 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. [a] If charge air cooler leaks are present around the joints, replace the charge air cooler; refer to section 17.5.1. [b] If the intake manifold leaks, repair intake manifold; refer to section 17.5.2.
[c] If neither charge air cooler nor intake manifold leaked, check the exhaust system; refer to section 17.6. 8. Inspect charge air cooler for leaks (hoses, clamps, etc.). 17.5.1 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 section 17.5.2.1. 3. If the intake manifold leaks, repair intake manifold; refer to section 17.5.2. 17.5.2 Air Intake Manifold Repair Perform the following steps to repair the air intake manifold: 1.
Remove the air intake manifold; refer to MBE 4000 Service Manual (6SE412), Air system chapter 6.1. (Rev. 2007) All information subject to change without notice. 17-16 From Bulletin 1–MBE 4000–07 6SE412 0702 Copyright © 2007 DETROIT DIESEL CORPORATION