Cat intercooler leak - TheDieselGarage.com
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post #1 of 9 (permalink) Old 08-29-2012, 01:01 AM Thread Starter
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Cat intercooler leak

One of the Peterbilt trucks in the fleet that I am in charge of keeping on the road seems to be having a problem with inter coolers, the original one started leaking about three weeks ago, I replaced that one and the truck made ONE trip.

When it got back I checked the cooler and found it leaking again, We sent it to a local Kenworth dealer, to have some injector work done, and they replaced the cooler again, now, about one week later it has started leaking again.

What I am looking for is ANY ideas as to what may be causing this.

Thanks in advance. Tom.
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post #2 of 9 (permalink) Old 08-29-2012, 01:35 AM
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Originally Posted by claymore1500 View Post
One of the Peterbilt trucks in the fleet that I am in charge of keeping on the road seems to be having a problem with inter coolers, the original one started leaking about three weeks ago, I replaced that one and the truck made ONE trip.

When it got back I checked the cooler and found it leaking again, We sent it to a local Kenworth dealer, to have some injector work done, and they replaced the cooler again, now, about one week later it has started leaking again.

What I am looking for is ANY ideas as to what may be causing this.

Thanks in advance. Tom.
Either it's overboosting (doubtful), or the radiator frame is twisted. I have seen KW's twisted and I had to shim the mounts so the bolts wouldnt draw it together and crack the solder joints.

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post #3 of 9 (permalink) Old 08-29-2012, 01:36 AM
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Poor workmanship either on the part of the cooler mfg of the guys that installed it, if the cooler isn't mounted right or the mount points are damaged it could cause problems, but the shop that installed it should check that kind of thing to avoid warranty hasssles.

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post #4 of 9 (permalink) Old 08-29-2012, 09:51 AM Thread Starter
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Maybe I should have specified, This is the "Cat" part, it mounts on the engine between the turbo and the water pump.

Also: Cat, put the first one on when the engine was built, I installed the second one, and the third one was put on by a Kenworth dealer, so it seems unlikely that the installer is at fault.
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post #5 of 9 (permalink) Old 08-29-2012, 10:58 AM
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If you would have specified what engine that would have helped, and that is actually a pre cooler to drop IAT to a reasonable level before it enters the air to air. Must be an ACERT, which that being said you don't hear of those leaking too often, where is the leak?

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post #6 of 9 (permalink) Old 08-29-2012, 10:10 PM Thread Starter
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Please, forgive my lack of useable info, I started the thread at 1 AM, and I was half asleep,

That being said, It is in fact a C-13 acert, The part in question is the pre cooler and the leak is internal, meaning the coolant is going thru the air intake right into the engine, there is coolant trails from all of the turbo hose connections on both sides of the air charge cooler.

And like I said in the OP, this will be the forth one on the engine in about a month.
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post #7 of 9 (permalink) Old 08-30-2012, 10:12 AM
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precooler bypass valve is not letting coolant flow through,which causes the precooler to overheat ,creating the crack.the bypass valve is the thing that bolts to the side with the solenoid in it.replace that whole unit and it should solve the problem.good luck
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post #8 of 9 (permalink) Old 08-30-2012, 10:26 PM Thread Starter
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precooler bypass valve is not letting coolant flow through,which causes the precooler to overheat ,creating the crack.the bypass valve is the thing that bolts to the side with the solenoid in it.replace that whole unit and it should solve the problem.good luck
Thank you, I believe the boss took the truck back to the Kenworth dealer where the last cooler was put on, I will check it when it get's back.
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post #9 of 9 (permalink) Old 09-07-2012, 12:13 AM Thread Starter
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precooler bypass valve is not letting coolant flow through,which causes the precooler to overheat ,creating the crack.the bypass valve is the thing that bolts to the side with the solenoid in it.replace that whole unit and it should solve the problem.good luck
Good call, We had Kenworth check the valve, and they said that it was not working.


Thank you
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