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Frequently Asked Questions - Non-Performing Charge Air Cooler Questions

Dura-Lite™ recommends that a Charge Air Cooler should be tested every time the vehicle is in for service and/ or when the oil is changed. It is vital to the performance and reliability of the engine that leaks are detected as soon as possible in order to reduce problems caused by a leaking Charge Air Cooler.

Dura-Lite™ estimates 40% of trucks 2 (two) years or older, have Charge Air Coolers that are leaking out of the engine manufacturers specifications.

Dura-Lite™ manufactures a Test Kit that includes all of the tools and instructions necessary to test most models, makes, and/ or sizes of Charge Air Coolers safely and accurately. Please reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website or printed Catalog for additional information on the basic procedure. Dura-Lite’s Part # is “Tester-Kit™” and the kit is available through Dura-Lite™ Distributors/ Dealers. The Distributor/ Dealer will provide your cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

Yes. Dura-Lite™ manufactures a Test Kit that includes all of the tools and instructions necessary to test most models, makes, and/ or sizes of Charge Air Coolers safely and accurately. Please reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website or printed Catalog for additional information on the basic procedure. Dura-Lite’s Part # is “Tester-Kit™” and the kit is available through Dura-Lite™ Distributors/ Dealers. The Distributor/ Dealer will provide your cost. Please contact Dura-Lite™ Customer Support at 800-661-1117 for information on a Distributor/ Dealer near you.

A leaking Charge Air Cooler results in incomplete combustion which causes; loss of engine power, increased fuel consumption, elevated soot levels in the oil, premature piston, ring, and valve failure, turbocharger failures, elevated coolant temperatures, and exhaust manifold failure.

Yes. The rule of thumb is to pressure the Charge Air Cooler up to 30 psig and that it should hold air for at least 15 seconds. If there is a pressure loss of 5 psig or more within the 15 seconds, the Charge Air Cooler is leaking out of specification (Leak Down Rate Specification) and it should be replaced immediately. This is only a guideline and it is very important to check the engine manufacturers Leak Down Rate Specification (some common specifications are noted below). Please also reference Dura-Lite’s Tester-Kit™ information page under the Products section of the Website for additional information on the basic procedure.

Leak Down Rate Specifications:

Caterpillar 5 psig in 15 seconds @ 30 psig
Cummins (ISB, ISC, N14) 7 psig in 15 seconds @ 30 psig
Cummins (ISX, M11)  5 psig in 15 seconds @ 30 psig
Detroit Diesel 5 psig in 30 seconds @ 30 psig
International 5 psig in 15 seconds @ 30 psig
Mack 5 psig in 15 seconds @ 30 psig
Mercedes 5 psig in 15 seconds @ 25 psig
Volvo 5 psig in 15 seconds @ 30 psig

            

               

           

                

   

 

* psig (pound-force per square inch gauge)

An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Leaking Charge Air Cooler Cost:


Fuel Cost Calculator: Leaking
Charge Air Cooler:
Dura-Lite™
Leak Free
Charge Air Cooler:
   
Fuel Cost $2.25 $2.25 Per Gallon US Gallons
Fuel Economy 5.5 5.9 MPG (Estimate)  
Average Trip Per Day 600 600 Miles   
Consumption Per Day 109.1 101.7 Gallons US Gallons
Cost Per Day $245.45 $228.81     *   
* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations. 

Dura-Lite’s calculation of the amount of fuel an engine is wasting as a result of a Leaking Charge Air Cooler and an operator could save with a Dura-Lite™ Leak Free Charge Air Cooler is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Dura-Lite™ Could Save An Operator:


Per Day* $17.00
Per Week* $85.00
Every 4 Weeks* $340.00
Per Year* $4,420.00
* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.

An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel an engine is wasting is approximately what is shown in the table below (based on a fuel cost of $ 2.25 per gallon).

* Please also reference Dura-Lite’s Leaking CAC Calculator page on the Website to find out what you can save!

Dura-Lite™ Could Save A Fleet:


Number Of Vehicles: 50 100 250 500 750 1,000
Per Day* $17.00 $850.00 $1,700.00 $4,250.00 $8,500.00 $12,750.00 $17,000.00
Per Week* $85.00 $4,250.00 $8,500.00 $21,250.00 $42,500.00 $63,750.00 $85,000.00
Every 4 Weeks* $340.00 $17,000.00 $34,000.00 $85,000.00 $170,000.00 $255,000.00 $340,000.00
Per Year* $4,420.00 $221,000.00 $442,000.00 $1,105,000.00 $2,210,000.00 $3,315,000.00 $4,420,000.00
* An engine with a leaking Charge Air Cooler will waste fuel. Dura-Lite’s calculation of the amount of fuel your engine is wasting is approximately what is shown above. The calculations are only approximate amounts based on a formula, using information from customer experiences with our products. Those experiences may be different from yours. The amount you save may be more or less than what is shown, due to other factors not reflected in the calculations. Dura-Lite™ does not warrant the accuracy of the calculations.