Section 10
--- Chassis Information
Cayman 2005
358
CHARGE AIR COOLER
Operation:
The diesel engine uses compression to ignite the fuel/air charge. To increase compression inside the
combustion chamber (resulting in increased power output) a turbocharger is added to the engine. The
turbocharger is a paired housing assembly with impellers inside each housing connected by a common
shaft. One impeller is propelled by the engine exhaust, which drives the other impeller. The function of
the other impeller is to increase compression inside the combustion chamber by forcing air into the
intake manifold. This process works well, however, the intake air charge is heated two different ways.
Through convection by the exhaust gases driving the turbocharger and any time air is compressed heat is
produced. This has a negative effect inside the combustion chamber resulting in lost power potential.
Therefore, a Charge Air Cooler (CAC) is installed to cool the intake air before it enters the engine. The
CAC performs the same function as a radiator, cooling air instead of liquid. Ambient air passing
through the CAC will cool the engine intake air charge.
After leaving the turbocharger, intake air is compressed and heated to approximately 300º to 375º F.,
depending on the engine load and throttle position. Before air enters the intake manifold, the CAC cools
the intake air temperature to the engine manufacturer specifications. Lowered intake air temperatures
reduce exhaust emissions, improve fuel economy and increase horsepower. The CAC will continually
expand and contract up to ¼" as throttle increases and decreases.
Cleaning & Maintenance:
Visually inspect the charge air cooler, every six months, for dirt and debris that may be blocking the
fins. If the motorhome develops an oil leak, there is a possibility that the oil will coat the fins of the
CAC. Dust will adhere to the oil film and eventually clog the fins, greatly reducing cooling efficiency.
When the oil leak is repaired, the CAC must be thoroughly cleaned.
During each oil change
inspect
the engine side of
the radiator/CAC assembly for foreign objects that
may cause restriction.
Spraying degreaser on the charge air cooler, as
well as using a steam cleaner, will not damage the
CAC. However,
pressure washer and steam clean-
er nozzles placed too close to the CAC can bend
the fins.
The recommended cleaning procedure for
the CAC and the radiator, is to use a bucket of mild
soap and water. Carefully wash with a bristle brush
then rinse using a garden hose, with minimum water
pressure, standing back a distance to avoid bending
the fins.
090388d
Summary of Contents for Cayman 2005
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Page 76: ...Section 2 Driving Safety Cayman 2005 76 100179D Weight Label...
Page 81: ...Driving Safety Section 2 Cayman 2005 81 020254 Cargo Carrying Capacity Flowchart...
Page 83: ...Driving Safety Section 2 Cayman 2005 83 020255k Actual Worksheet...
Page 84: ...Section 2 Driving Safety Cayman 2005 84 Weight Record Sheet...
Page 85: ...Driving Safety Section 2 Cayman 2005 85...
Page 86: ...Section 2 Driving Safety Cayman 2005 86 010725 010726c VIEWS Front Rear...
Page 87: ...Driving Safety Section 2 Cayman 2005 87 010723f 010724e Roadside Curbside...
Page 95: ...Driving Safety Section 2 Cayman 2005 95 NOTES...
Page 96: ...Section 2 Driving Safety Cayman 2005 96 NOTES...
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Page 108: ...Section 3 Exterior Interior Care Cayman 2005 108 Fabric Specifications Charts...
Page 109: ...Exterior Interior Care Section 3 Cayman 2005 109...
Page 134: ...Section 3 Exterior Interior Care Cayman 2005 134 NOTES...
Page 136: ......
Page 165: ...Appliances Section 4 Cayman 2005 165 NOTES...
Page 166: ...Section 4 Appliances Cayman 2005 166 NOTES...
Page 168: ......
Page 203: ...Equipment Section 5 Cayman 2005 203 NOTES...
Page 204: ...Section 5 Equipment Cayman 2005 204 NOTES...
Page 206: ......
Page 229: ...Water Systems Section 6 Cayman 2005 229 WATER SYSTEM DIAGRAM 040487c Typical Layout...
Page 230: ...Section 6 Water Systems Cayman 2005 230 NOTES...
Page 232: ......
Page 250: ...Section 7 LP Gas Systems Cayman 2005 250 NOTES...
Page 252: ......
Page 286: ...Section 8 Electrical Systems House Cayman 2005 286 NOTES...
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Page 292: ...Section 9 Electrical Systems Chassis Cayman 2005 292 080427f 080387C 080388c...
Page 315: ...Electrical Systems Chassis Section 9 Cayman 2005 315 ENGINE NO START FLOW CHART...
Page 316: ...Section 9 Electrical Systems Chassis Cayman 2005 316 NOTES...
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Page 376: ...Section 10 Chassis Information Cayman 2005 376 LUBRICATION CHARTS 070166G FRONT...
Page 382: ...Section 10 Chassis Information Cayman 2005 382 METRIC U S CONVERSION CHART...
Page 384: ...Section 10 Chassis Information Cayman 2005 384...
Page 385: ...Chassis Information Section 10 Cayman 2005 385...
Page 386: ...Section 10 Chassis Information Cayman 2005 386...
Page 387: ...Chassis Information Section 10 Cayman 2005 387...
Page 389: ...Cayman 2005 INdex...
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