Charge Air Cooler Leak Test, Checking - Volvo D12 Service Manual

Group 25 Intake and Exhaust System
2651-06-04-01
Charge Air Cooler Leak Test,
Checking
If the turobocharger fails on an intercooled engine, it is
essential to check the charge air cooler. When consider-
able oil loss or the presence of foreign material (for
example, broken compressor wheel parts forced into the
charge air cooler) is suspected, take the following mea-
sures:
Check the charge air cooler hoses up to the cooler. If
there are traces of oil at the charge air cooler, remove
the cooler and clean it internally, using a low-aroma,
white-spirit type degreasing agent.
If turbocharger failure results in a broken compressor
whell, pressure-test the charge air cooler to see if it has
been damaged by broken compessor wheel pieces.
Special tools: 9996662, 9998288, 9998289
Note: Check the function of pressure gauge 9996662
before using it. Attach it to an air supply and set the
pressure to 100 kPa (14.5 psi) with the regulator valve.
Before working on a vehicle, set the parking brakes,
place the transmission in neutral, and block the
wheels. Failure to do so can result in unexpected
vehicle movement and can cause serious personal in-
jury or death.
WARNING
HOT ENGINE! Keep yourself and your test equipment
clear of all moving parts or hot engine parts and/or
fluids. A hot engine and/or fluids can cause burns or
can permanently damage test equipment.
WARNING
Never disconnect an air system component unless all
system pressure has been depleted. Failure to de-
plete system pressure before disconnecting hoses or
components may result in their violent separation and
can cause serious bodily injury.
WARNING
Make sure that the gauge pressure never exceeds
100 kPa (14.5 psi). Failure to do so can result in
personal injury.
WARNING
—Always wear appropriate eye protection to prevent
the risk of eye injury due to contact with engine debris
or fluids.
1
Fig. 50: Pressure gauge
1 Shut-Off Valve
2 Reduction Valve
Connect the pressure gauge to out-
side air source and set the gauge
reading to 100 kPa (14.5 psi) using
the reduction valve. The knob of the
reduction valve is locked by a ring
which is engaged by pulling up on the
ring, and pushing down to release.
2
Close the shut-off valve. For the pres-
sure gauge to be considered reliable,
the pressure reading must not drop
during a period of two minutes.
Service Procedures
W2000715
39