Charge Air Cooler

[skyguy62]

Two years 11 months into debugging finds me in the Cummings Coach Care Facility in EL Cajon, CA.. In the last couple months both support brackets on the Turbo Charger pipes have broken, allowing them to lay on the engine. Performance in acceleration was notably sluggish. During a round trip (CA to NH) I fixed both brackets sent to me by WRV; but the installation is a POOR design; one is showing bending already. With the lousy performance I remembered write ups here about cracks in the boots at the ends of the pipes, so we came here to checkout the system. Boots were ok as were the joints so they did a pressure test and found extensive cracking on the entry side of the charge air cooler (outermost radiator in the sandwich).Coach care said they are seeing 5 or 6 a month now all failing in the same manner.

The air entering from the Turbo is at 300+ degrees while the accelerator is depressed (cooling to near 150 when released). The air exits at 100 degrees. The heating and cooling is causeing the aluminum to seperate. With the engine running you will not hear the air escaping, it is undeniable when the test eqiupment is used to pressurize the line. Coach Care has had problems with the equipment supplied by "Radiator Specialties" in CA; they have ordered a new modle from Canada.

WRV has not responded to CC since last Tuesday nor responded to my calls last Friday, hopefully they are just distracted. My Coach is an "05" FDQS

[skyguy62]

Two years 11 months into debugging finds me in the Cummings Coach Care Facility in EL Cajon, CA.. In the last couple months both support brackets on the Turbo Charger pipes have broken, allowing them to lay on the engine. Performance in acceleration was notably sluggish. During a round trip (CA to NH) I fixed both brackets sent to me by WRV; but the installation is a POOR design; one is showing bending already. With the lousy performance I remembered write ups here about cracks in the boots at the ends of the pipes, so we came here to checkout the system. Boots were ok as were the joints so they did a pressure test and found extensive cracking on the entry side of the charge air cooler (outermost radiator in the sandwich).Coach care said they are seeing 5 or 6 a month now all failing in the same manner.

The air entering from the Turbo is at 300+ degrees while the accelerator is depressed (cooling to near 150 when released). The air exits at 100 degrees. The heating and cooling is causeing the aluminum to seperate. With the engine running you will not hear the air escaping, it is undeniable when the test eqiupment is used to pressurize the line. Coach Care has had problems with the equipment supplied by "Radiator Specialties" in CA; they have ordered a new modle from Canada.

WRV has not responded to CC since last Tuesday nor responded to my calls last Friday, hopefully they are just distracted. My Coach is an "05" FDQS