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SERIES 60 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. Test the charge air cooler; refer to section .
  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 section .
    2. If the intake manifold leaks, repair intake manifold; refer to section .
    3. If neither charge air cooler nor intake manifold leaked, check the exhaust system; refer to section .

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 .
  3. If the intake manifold leaks, repair intake manifold; refer to section .

Air Intake Manifold Repair

Perform the following steps to repair the air intake manifold: ‪

  1. Remove the air intake manifold; refer to section .
  2. Inspect the air intake manifold; refer to section .
  3. Install the air intake manifold; refer to section .
  4. Verify repair of the intake manifold; refer to section .
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: ‪

  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 section .