Exhaust Manifold Leak and Charge Cooler Leak Test

[gandl2]

I am looking for some recommendations. I have my '02 Alpine model 34 in for general service at Cummins Coach Care in ElCajon. They called me today to tell me that the Exhaust Manifold (EM) gaskets are leaking and should be replaced. They also want to do a charge cooler leak test to determine if there is a problem with the CAC that may have caused the gasket issue. They say the CAC test will be 2 1/2 hrs, and the replacement EM gasket will take 6 hrs. What should I have them do?

[gandl2]

I am looking for some recommendations. I have my '02 Alpine model 34 in for general service at Cummins Coach Care in ElCajon. They called me today to tell me that the Exhaust Manifold (EM) gaskets are leaking and should be replaced. They also want to do a charge cooler leak test to determine if there is a problem with the CAC that may have caused the gasket issue. They say the CAC test will be 2 1/2 hrs, and the replacement EM gasket will take 6 hrs. What should I have them do?

[J R Sprague]

The middle of January we had our 2000 coach in for service at Cummins in El Cajon. Took a couple of extra days since they found a loose turbo with a blown gasket and a weak lift pump. They did test the charged air cooler and it was fine. They were willing to reinstall the turbo however noted it was a little out of balance. I decided to have a new turbo installed after inspecting the roughness of the impeller on the turbo. Traveled to Irvine myself and picked up the turbo to save a day since we were already late for arriving at the desert rat rally. Hope the spelling and grammer are correct because I still need to find a spell check in this system.

[Old Scout]

Other members of the club may have more of a technical view to offer but we had similar problems with our 2003 (late 2002). Several years ago, a cross tube ruptured in the CAC--no reduction in power but you sure could hear it. About a year ago, we had an exhaust manifold gasket leak. Again, you could hear it as the leak was near a cylinder exhaust port so there was a pulsing sound [and a black carbon mark on the EM]. In yr case, I dont see any causal relationship between the EM gasket leak and a possible CAC leak. Seems that in either case, a combination of visual inspection and a check of the boost levels [via computer?] would determine if you have any "charge air" leaks....

[skyguy62]

Somewhere in the files is an entry by me on my CAC. My 05 FDQS was being beaten off the mark at every stop light or sign by a pack of wild slugs! Their trailing laughter sent me to the same El Cajon for a checkup. I had both brackets that support the two steel air tubes of the Turbo system break allowing the pipes to lay on and bounce off of the engine. Fearing cracks in the end boots or possible tiny holes in the pipes I went for a test. Not cheap but effective I saw the results (air flow and escaping air noise)of an apparent CAC failure (Crack in inlet boot area. I was told by Cummings that I shouldn't drive very far without fixing it. That was Nov 4th!!!! 1. The CAC has a one year warranty (no extension by the WRV warranty. 2. CAC manufacturer is out of business (bankruptcy). 3. Other avail units probably wont fit in the three unit radiator sandwich. 4Cummings said most people never notice the CAC leak untill"exhaust gaskets fail.
5. A company in Canada has offered to recieve my unit -cut it up - and reverse engineer it- then manufacture a replacement CAC to fit the sandwich. Estimate 7 to 8 weeks NOT good news for a fulltimer!
Chris at WRV called last week to say he may have a lead on a spare unit someplace. I am 4 months into sitting around and have only 2 1/2 months till I get to cancel a trip to Canada for the Summer. This will not probably give you any solace but will alert others to the potential problem Maybe we can get a package plan from Canada.

[1peddler]

Sky guy,

For reference, who was the orginal mfg of the CAC. Was it radiator specility in Sacramento, CA.

[andye]

I read this and I had to put my two cents worth in on the subject. I found the exhaust manafold gaskets leaking I called cummins thay said 6 to 8 hrs. labor. I went to cummins got the parts $17.50x6 spent 2hrs putting them in thinking what do thay do for the rest of the time? I thought thay went out from the back pressuer from exhaust brake. It is a very easy job the only tool people don't have to do this job is a tork wrench. I also replaced the bolts some of them were stretched thay were $1,50 each x12. It could have taken a lot more time if I would have broken a bolt. I have put on 5000mi and no leaks. time will tell.

[skyguy62]

"I Peddler" yes I believe they were the original manufacturer of the CAC.