Hello to all. My first post...The dealership is telling me that my 2001 with 55,000 miles has a bad charge air cooler by virtue of the fact that "it doesn't hold pressure". they are suggesting that it was damaged by road debris or some such catastrophe. A new one is $800.00 plus labor ( around 8 hours). The vehicle has been great until just before Thanksgiving when the accelorator switch went and stranded me in Fishill New York while Cummins made the part. Anywho, I digress....Last week it started to smoke and lose power...Bad Fuel?...only intermittently. HELP!!!

 

They are full of it IMHO. No way I would fork over that kind of cash to a dealer for a non-issue.

I "assume" that when you say charge air that you mean the intake?

I didn't even know there was any knid of pressure that was supposed to be built in there.

There are much better ways to replace and furthermore upgrade the intake.

Matt

 

The charge air cooler would be the intercooler in front of the radiator. If it is leaking it will cost you performance. I would check for better prices. It changes out just about like a radiator, should not be too bad a job to change it.

 

The smoke and loss of power would indicate a problem in the intercooler be it a hose connection or the intercooler itself. Get them to check to be sure its indeed the cooler or just a blown boot.

The intercooler is made of aluminum, any good rad shop should be able to repair any punctures to it. Even if they have to pinch a tube, you would be fine until such time as you want to replace it.

J-eh

 

This is very good advice. You (original poster) mentioned though that your problem was intermittent. A leak in the charge air cooler large enough to cause your symptoms would probably cause a consistent problem. If you can mash the trottle up a steep hill in OD and sometimes NOT experience the problem, I'd be looking for different or additional solutions.

 

I think before I forked over 800 bucks for a intercooler, and who knows how much for labor, I would do a little investgating on my own. First, the lower boots that connect the intercooler to the pipe from the turbo, are known to rub and wear thru, causing them to leak. The one one the passenger side (inlet to the cooler) is the worst, but check both. Then there is the boot that comes off the turbo and another that connects the intake, check them out.
Also look for other not so obvious areas. If you have a boost guage, make sure the line is intacked.

 

Sometimes the intercooler does spring leaks where the core attaches to the ends and can't be repaired. If I recall Piers Diesel 866-888-9396 sells them for around $400.

8 hours??? I could do it half the time with just a Swiss Army knife.

 

Ahh, thanks for the education!

Guess after reading all of the replies I might suggest looking at the boots as well.

Matt

 

Thanks folks. It turns out the fuel pump is supposedly bad too. Warranty repair(yipee). I told them to do the warranty work and I'd do a bit more research on the intercooler.
What is typical stock engine turbo boost pressure?

 

I believe that with a stock 2001 you are wastegated at around 20 to 22 psi, and I am fairly certain it depends on which tranny you have.

I am sure others will chime in to correct me if I am wrong.

Matt