Charge air cooler

[JOC1212]

We have a 2000 Intrigue with 36K miles and are having to replace the Charged Air Cooler and exhaust manifold due to cracks and leaks. Is this a common problem? The coach is at Cummins Northwest in Coberg, OR waiting 8 weeks for a new cooler from Country Coach. Anyone have any info they'd like to share on this issue?

[JOC1212]

We have a 2000 Intrigue with 36K miles and are having to replace the Charged Air Cooler and exhaust manifold due to cracks and leaks. Is this a common problem? The coach is at Cummins Northwest in Coberg, OR waiting 8 weeks for a new cooler from Country Coach. Anyone have any info they'd like to share on this issue?

[MonacoMama]

Let me see if I can reach a gentleman who has a 1998 CC. He seemed to mention something about this to me...and if it is the same thing - it was a known problem.

MM

PS... You must be AmyAnn's other half...correct?

[JOC1212]

Thanks for your help...
I'm Amy Ann's dad (she's our Golden Retriever) I just changed out profile to show us as JOC since the Amy Ann name was giving people the wrong impression. Mickey and Rick thought the Amy Ann was cute when she got us all signed up but too many people think she is a person and she keeps wanting me to read the emails to her.

[MonacoMama]

I have been playing 'phone tag' with the previously mentioned folks off & on all day. The last contact made was that we will make contact on Sunday...so I may have something for you tomorrow.

By the way...I knew AmyAnn is the retiever and you are a FF...and I am NOT surprised she wanted either one of you to read the emails to her!


MM

[JOC1212]

She watches TV and loves animal planet and the cooking shows...she is bored with the politics since neither canidate has mentioned anything about mandatory frisbee throwing sessions being required of keepers of Golden Retrievers.

[quikduk]

Here is what I know about Charge Air Coolers (CAC).

1. they are fragile compared with radiators

2. they need to be cleaned with "gentle" water pressure, not pressure washers

3. they can develop cracks due to overtightening of those special clamps (which are designed to NOT overtighten but you know...)

4. if one cracks, it must be repaired or replaced as you will lose a significant amount of power and possibly damage the turbo.

5. the CAC is designed to cool and thus aid in the compression (further) and efficiency of the incoming air charge prior to fuel atomization and then combustion. CAC equipped turbo-diesels have more power than non-CAC equipped ones.

Mine doesn't have any cracks (that I know of) but I am still trying to remove all of the slobber tube grease (before I lengthened the short factory tube). My next step would be total removal and if it comes to that, I will get it boiled out and checked for leaks as well as the radiator.

FWIW, I would have your radiator rodded and boiled out while you have this stuff apart and possibly have the new CAC boiled out as well just in case there is some manufacturing junk left in there.

Re: the exhaust manifold, I have heard of some people having these issues and it is not uncommon considering the heat in the engine bay. Unless there was a mfr. defect, the manifold may have cracked due to overtightening or overheating. In both cases, the mating surface of the head should be checked for a smooth, square surface prior to the manifold being installed (and ditto for the manifold mating surface) plus ALL of the exhaust studs/bolts must be replaced with NEW due to heat temper and stretch issues.

There. You just got a lot of my experience for only $.02. Not a bad deal IMHO.

Good luck.

[JOC1212]

Thanks so much for your input... It is being printed and going in my MH file.

[Lindsay Hargett]

I have seen this problem a few times and you are not waiting on Country Coach your waiting on I'm assuming radiator specialists to build one for you. Your coach is 8 years old this would not be uncommon, usually they replace the radiator as well. Lindsay Hargett Guaranty Rv