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.
[a] If charge air cooler leaks are present around the joints, replace the charge air cooler;
refer to section 12.7.1.
[b] If the intake manifold leaks, repair intake manifold; refer to section 12.7.2.
[c] If neither charge air cooler nor intake manifold leaked, check the exhaust system;
refer to section 12.8.
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 section 12.7.2.1.
3. If the intake manifold leaks, repair intake manifold; refer to section 12.7.2.
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 section 12.7.2.1.
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:
1. Start and run the engine.
2. Test drive the vehicle to ensure lack of power has been resolved.
[a] If no lack of power occurred during the test drive, no further troubleshooting is
required. Shut down the engine.
[b] If lack of power occurred during the test drive, shut down the engine. Check the
exhaust system; refer to section 12.8.
