Diagnosis And Testing - Charge Air Cooler System - Leaks; Cleaning - Dodge Sprinter 2006 Manual

VA
OPERA TION
In t a ke a ir is dr a wn t h r ou gh t h e a ir clea n er a n d
in t o t h e t u r boch a r ger com pr essor h ou sin g. P r essu r-
ized a ir fr om t h e t u r boch a r ger t h en flows for wa r d
t h r ou gh t h e ch a r ge a ir cooler loca t ed in fr on t of t h e
r a dia t or. F r om t h e ch a r ge a ir cooler t h e a ir flows
ba ck in t o t h e in t a ke m a n ifold.
DIAGNOSIS AND TESTING - CHARGE AIR
COOLER SYSTEM - LEAKS
NOTE: Slight engine oil pooling in the charge air
inlet hose IS NOT premature turbocharger failure.
Slight pooling is the normal result of the breather
system. Test the air breather tube for normal oper-
ation by referring to the appropriate diagnostic
manual.
Low t u r boch a r ger boost pr essu r e a n d low en gin e
per for m a n ce ca n be ca u sed by lea ks in t h e ch a r ge a ir
cooler or it 's plu m bin g. Th e followin g pr ocedu r e ou t -
lin es h ow t o ch eck for lea ks in t h e ch a r ge a ir cooler
syst em .
(1) Loosen cla m p a n d r em ove t u r boch a r ger t o a ir
in let du ct r u bber sleeve fr om t u r boch a r ger.
(2) In ser t Specia l Tool 8442 Ada pt er in t o t h e r u b-
ber sleeve. Tigh t en exist in g cla m p t o 8 N·m (72
in .lbs.).
CAUTION: Do not apply more than 138 kpa (20 psi)
air pressure to the charge air cooler system, sever
damage to the charge air cooler system may occur.
(3) Con n ect r egu la t ed a ir su pply t o a ir fit t in g on
Specia l Tool 8442 Ada pt er. Set a ir pr essu r e t o a Ma x-
im u m of 138 kpa (20 psi).
(4) Usin g soa py wa t er ch eck t h e a ir in let du ct s,
r u bber sleeves, ch a r ge a ir cooler a n d in t a ke m a n ifold
for lea ks.
REMOVAL
(1) Rem ove fr on t bu m per.
(2) Rem ove h ea dla m p a ssem blies.
(3) Rem ove fr on t cr oss m em ber t oget h er wit h fr on t
gr ille.
(4) Rem ove left a n d r igh t r a dia t or t r im (F ig. 3).
(5) Discon n ect ch a r ge a ir h oses a t ch a r ge a ir cooler
(F ig. 3).
(6) Discon n ect power st eer in g cooler loop fr om
ch a r ge a ir cooler (F ig. 3).
(7) Rem ove ch a r ge a ir cooler fr om r a dia t or a ssem -
bly (F ig. 3).
Fig. 3 CHARGE AIR COOLER
1 - POWER STEERING COOLER LOOP
2 - CHARGE AIR HOSE
3 - CHARGE AIR COOLER HOSE
4 - CHARGE AIR COOLER
5 - LEFT RADIATOR TRIM PANEL
6 - RIGHT RADIATOR TRIM PANEL

CLEANING

CAUTION: Do not use caustic cleaners to clean the
charge air cooler. Damage to the charge air cooler
will result.
NOTE: If internal debris cannot be removed from
the cooler, the charge air cooler MUST be replaced.
(1) If t h e en gin e exper ien ces a t u r boch a r ger fa ilu r e
or a n y ot h er sit u a t ion wh er e oil or debr is get in t o t h e
ch a r ge a ir cooler, t h e ch a r ge a ir cooler m u st be
clea n ed in t er n a lly.
(2) P osit ion t h e ch a r ge a ir cooler so t h e in let a n d
ou t let t u bes a r e ver t ica l.
(3) F lu sh t h e cooler in t er n a lly wit h solven t in t h e
dir ect ion opposit e of n or m a l a ir flow.
(4) Sh a ke t h e cooler a n d ligh t ly t a p on t h e en d
t a n ks wit h a r u bber m a llet t o dislodge t r a pped
debr is.
(5) Con t in u e flu sh in g u n t il a ll debr is or oil a r e
r em oved.
(6) Rin se t h e cooler wit h h ot soa py wa t er t o
r em ove a n y r em a in in g solven t .
(7) Rin se t h or ou gh ly wit h clea n wa t er a n d blow
dr y wit h com pr essed a ir.
EXHAUST SYSTEM 11 - 5