2 0 0 8 K n I G h t
chassIs InformatIon — 10
21
This process works well, however, the intake
air charge is heated two different ways: through
convection by the exhaust gases driving the
turbocharger and when air is compressed. This
negative effect inside the combustion chamber
results 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 and Maintenance:
Regular maintenance includes draining
the engine coolant, flushing/cleaning
the cooling system,
inspecting
the
water pump standpipe, replacing the
thermostat, gasket and seal, and replacing
the coolant and SCA element.
Inspect
the charge air cooler every six
months and remove dirt and debris that
may block 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, clog the
fins and reduce 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 cleaner
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.
When performing maintenance, it is also
necessary to
inspect
other components of
the cooling system. The charge air cooler
and radiator also requires an
inspection
for cracks, broken welds, secure
mounting, and general cleanliness.
Coolant Hoses:
Inspect coolant hoses and connections when
checking engine or transmission fluids. Look for
any signs of chaffing at hose restraints or sharp
edges. Indications that hoses have reached the
end of service life included cracking or swelling
around clamps and connections. Oil leaks can
also deteriorate hoses. Overheating can be
caused by a collapsed hose or a clog caused by
rubber shedding from a rotten hose. Replace any
hose found to be cracked, swollen or damaged.
Connections should be
inspected
periodically
and hose clamps tightened.
Every 12 months:
Inspect
all hoses, clamps, and fittings for leaks
due to cracking, softness, and loose clamps/
fittings. Look for signs of fluid leaks, damaged
end fittings, ballooning, chafed, kinked, or
crushed hoses, and loose clamps and fittings.
Correct any deficiencies found.
rear grIll
The rear grill pulls out for access to the
radiator compartment. The grill is attached by
four tabs that insert into four grommets, one on
each corner. To detach, place both hands evenly
spaced on the grill and gently ease the grill out.
To reinstall, align the tabs with the grommets
and push in.
WARNING
When reinstalling it is IMPORTANT
that the four corners of the grill are
securely attached to the four grommets.
Failure to do so may result in the grill
jarring loose with travel.
090496d
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