Charge-Air Cooler Repair

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If you own a big truck with a charge-air cooler, you NEED TO READ THIS! 

RJR Radiator is set up to clean, test & repair charge-air coolers.  We can also RE-CORE your existing charge-air cooler.  Bring your truck by to let us test your charge-air cooler to see if it is causing you more problems than you realize!

COMMON PROBLEMS ASSOCIATED WITH NON-PERFORMING CHARGE AIR COOLERS*

LOSS OF ENGINE POWER

                    -NOT ENOUGH BOOST DENSITY FOR COMPLETE COMBUSTION.

INCREASTD FUEL CONSUMPTION

-INCOMPLETE COMBUSTION RESULTS IN UNBURNED FUEL BEING EXHAUSTED INSTEAD OF BEING USED FOR POWERING THE ENGINE.

EXHAUST MANIFOLD FAILURE

-UNBURNED FUEL IGNITES IN THE EXHAUST MANIFOLD AND ELEVATES THE EXHAUST TEMPERATURES.

-TRUCK MANUFACTURERS HAVE REPORTED TRUCK FIRES DUE TO OVERHEATED EXHAUST SYSTEMS CATCHING OTHER COMPONENTS ON FIRE WHICH DIRECTLY RESULTED FROM THE UNBURNED FUEL IGNITING IN THE EXHAUST MANIFOLDS.

PREMATURE PISTON, RING AND VALVE FAILURE

-LACK OF BOOST DENSITY PREVENTS SUFFICIENT COOLING OF THE CYLINDER WALLS DURING THE INTAKE STROKE.

ELEVATED COOLANT TEMPERATURES

-INSUFICIENT COOLING OF CYLINDER WALLS RESULTS IN ELEVATED BLOCK TEMPERATURES AND ADDITIONAL HEAT BEING ADDED TO THE COOLANT.

TURBO CHARGER FAILURE

-INSUFFICIENT BACK PRESSURE DUE TO CHARGE AIR COOLER LEAKS RESULTS IN THE TURBO SPINNING AT MUCH HIGHER REVOLUTIONS THAN ORIGINALLY DESIGNED FOR.

The basic purpose of a charge air cooler is to provide cool dense air (boost) to the engine. The maximum allowable intake manifold temperature and pressure loss is specified by the engine companies to ensure that the required boost temperature and density are maintained. Pressure losses have a greater impact on boost density than temperature which means a leaking charge air cooler would have the greatest impact on performance and ultimately the life of the engine.*

*This information was taken from a DURA-LITE Brochure.