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Charge Air Coolers - Common Failures  Unless your charge-air-cooler was damaged in an accident, or a rock went through the core, check these areas out first if you suspect a problem. Because of the amount of business Fleet Air does in rebuilding charge-air-coolers, we see many different types of failures. Shown below, you will see some of the more common failures. Failure #1: Separation of Top Plate From Header Plate  This is a common failure on some brands of OEM charge-air-coolers. It is caused by the top plate being too rigid to withstand the vehicle vibrations from the road, and compounded by increased temperatures.Fleet Air Technologies, Inc. has found that cutting expansion slots into the top plate will allow movement and minimize this type failure. We have also found that this condition can be caused by the closing of the waste gate on the turbo charger. When this is occurs, the increased pressures create much more stress where the top plate is attached to the header plate. The cooler was not designed for these extreme pressures. The only remedy for this is to ensure that the waste gate remains open during engine operation. Failure #2: Corrosion of the Core  Failures from corrosion are usually found in the northern states where salt is used on the roads during the winter months. This condition can also affect radiators, and other aluminum cooling units. Some OEM manufactures use anti-corrosion materials to protect the core, but there are those that do not use any protective coatings. Although the core of the charge-air-cooler will eventually deteriorate, you can significantly extend the life of the cooler by periodically and thoroughly cleaning the salt deposits from it with a detergent and power washer set to a lower pressure. It is also important to note that as the core deteriotes, it will begin leaking, which will lead to higher fuel bills and loss of engine power. Failure #3: Tube Distortion  These are three examples of failures due to the distortion of the cooling tubes. This type failure is caused by the internal fins of the tubes not being brazed properly, therefore allowing to the tubes to expand and crack.In our studies, we found this situation to be more prevalent on higher horsepower engines.  Failure #4: Failure of Tube Wall  The tubes of a charge-air-cooler are a critical part of the unit. They must be able to withstand high pressures and temperatures in various operating conditions. Some coolers are manufactured using too thin of a material for the tubes. The picture at the right demonstrates the effect of road damage and salt corrosion on a charge-air-cooler that was manufactured using too thin of material for the tubes.
Failure #5: Breakdown of Repair Materials  This charge-air-cooler had been repaired by someone, or company who used an inferior material to stop the leaks where the core is welded to the header plate. Because of heat, the repair material’s chemical composition broke down and became brittle as seen in the picture to the right. These types of repairs are only temporary and are more costly over the long term.
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998 Railroad St. NW |
