It has been suggested to me that part of my lack of power and overheating on hills only could be due to a clogged or leaking intercooler. Tomorrow I am having a radiator coming clean out and do a pressure check.
However, I talked to a few radaitor people and they think intercoolers are hard to hurt. They say usually these things dont cause problems. I should mention that I have 190 injectors (bosch) relatively new and a good Bhaf and no oil leaks. I also have a new radiator. What else could it be? Have any of you had issues with your intercooler and what was the symptoms.Thanks

 

It's relatively easy to leak check them. They don't get clogged unless some foreign objects (shop rag, etc.) get left in the ducting. What kind of boost pressure are you seeing?

 

I do not have a boost gauge. Can I test it without removing it?

 

Yes. Just remove the intercooler piping and you can cap the ends and pressurize it. If you air it up to 25 psi it should not lose more than 7 psi in 20 seconds. Any more pressure drop than that and Cummins says it is too leaky.

 

So if it does show a small leak or something could this make it loose so much power and get so hot going up long grades?

 

It would take a good sized leak to cause the problems you are describing, and I think you would hear a leak that big. The sound is usually like a BIG air compressor leak!

 

Here is something simple To check First.
Check the 2 Rubber hoses coming in and out of the intercooler to make sure they are not leaking around them or that they are not cracked. Then check that the air filter is not clogged on you.
Wheelo

 

I checked the hoses and clamps. They seem to be tight and I do not see any cracks. When I pull hills with a load there is a different sound. Because I cannot watch up close while in this situation, it sounds similar to the turbo but under stress. Thats the best way I can explain it.

 

Are you running any gauges? What size exaust are you running. With 190s your stock exaust may be too restrictive. What are your EGT's? With more fuel you need more air. Sounds like you may need more air flow and 4" exaust will help.JMO.

Greg

 

I sprayed some carburetor cleaner around hoses at intercooler connection while runnin at idle. The rpms went up alittle, maybe 100-200 rpms. It seems I do have some size of boost leak. I will be talking off and looking for cracks. It doesnt seem loose. Anyway I would like to thing this is whats robbing my power and causing very high heat.

 

Before you pull the intercooler!!!!!

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