Can a Bowman charge air cooler become clogged on the air side?

Murv

Murv

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As title really.
This is following on from an ongoing problem with low boost pressure, a new turbo and injectors has increased boost from 2.5 psi to 7, but it's still some way short of the correct operating pressure of 12psi.
Can the air cooler become clogged?
 
Yes, can become clogged with soot from a leaking exhaust.... strip down and clean out with paraffin. (don't ask me how I know)
HOWEVER... unlikely to affect the boost pressure by that much, 1psi is more likely.
Suggest that you look at whether the prop is loading the engine sufficiently.
OR leaky piping.
 
Thanks for that, it seemed unlikely to me but maybe it would benefit from a clean anyway. The old turbo had been spitting oil into the cooler for an unknown amount of time
The prop is loading the engine, max rpm is 4000, it's only achieving 3100. But, it's a big improvement on the 2500 it was making before at 2.5psi.
I need to go over the piperwork again, and check the vacuum tube to the pump. They were OK, but with all the work that's been undertaken, it's possible something has been holed or become loose.
I was just thinking out loud really, where to go from here really if everything checks out OK.
 
Has the inj pump got a boost capsule on top, ie is there a small pipe from the top of the pump over to the turbo somewhere?
 
lynall said:
Has the inj pump got a boost capsule on top, ie is there a small pipe from the top of the pump over to the turbo somewhere?
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I don't know if it's a boost capsule, but apparently there is a rubber hose that runs from the injection pump to the inlet manifold. It's supposed to increase fueling as boost pressure rises, is that a boost capsule? (Bosh VE mechanical pump) It's one of the things I need to carefully check, hopefully it's just that causing issues.
I was just wondering if the charge cooler could be clogged if it isn't something simpler.
 
if the turbo has been spraying oil into the intercooler it could be quite bunged up, also the pressure pipe from the inlet manifold to the fuel injection pump could be blocked too - that would take the performance off quickly
 
kashurst said:
if the turbo has been spraying oil into the intercooler it could be quite bunged up, also the pressure pipe from the inlet manifold to the fuel injection pump could be blocked too - that would take the performance off quickly
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Good to know, thank you. I don't know how much oil it's been passing, but there was a small pool on the compressor side of the turbo when it was removed so it was a reasonable amount.
I'll check that the pressure pipe isn't clogged, I was going to check it again for splits but hadn't thought to check it might be partially blocked!
 
omega2 said:
clean it out regular, easy job, remove from engine, remove end plates, stand case on wood blocks, tap out matrix, steam clean and reassemble, use new rubbers if needed do it once and then the next time will bee easy. Are you blowing black smoke out the back as well??

take a look at the drawings here



http://www.ejbowman.co.uk/products/MarineSpares.htm
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Thanks for that, looks straightforward then if it comes to it :)
Yes, there is Black smoke now at WOT.
 
Bosch ve pump, excellent thing as fitted to just about every land rover tdi from 1989 to 1998 easy to tune as well.
If you have a pipe to the manifold you have a boost capsule, the diaprhagm can split but more likely is the fuel pin can seize or partially seize, so you are getting some extra boost= extra fuel but not the full monty.
On the back of the capsule is a little rubber nipple this allows air displacement as the boost rises and falls, unfortunately it also allows damp air in and water in my land rovers case!
Google tuning the bosch ve pump, real simple and loads of good guides out there.
Depending on where your engine breather pipe is routed may determine if theres any oil in the inlet pipework, in fact ive never seen any small diesel without oil in the intercooler pipework.
 
omega2 said:
do it that will be the cause!! and as the muck builds up you will not be able to attain WOT.
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I'll do that, thank you. From the paint on the screws, its not ever been done so it must be due a clean anyway.

lynall said:
Bosch ve pump, excellent thing as fitted to just about every land rover tdi from 1989 to 1998 easy to tune as well.
If you have a pipe to the manifold you have a boost capsule, the diaprhagm can split but more likely is the fuel pin can seize or partially seize, so you are getting some extra boost= extra fuel but not the full monty.
On the back of the capsule is a little rubber nipple this allows air displacement as the boost rises and falls, unfortunately it also allows damp air in and water in my land rovers case!
Google tuning the bosch ve pump, real simple and loads of good guides out there.
Depending on where your engine breather pipe is routed may determine if theres any oil in the inlet pipework, in fact ive never seen any small diesel without oil in the intercooler pipework.
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Thanks for that. The breather just vents to atmosphere in it's current configuration. The previous owner ran it with no air filter so I've fitted a length of silicone hose and a cone filter to protect the vanes on the turbo.
I can't see a pipe coming off the pump, but I don't know if it's come off or just never had one! EDIT: Found it...
 
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When you sort the engine breather out make sure it is away from the turbo intake, or it just breathes it's own foul air, and the filter on the turbo could also be a problem, so make sure that it is clean also.
 
omega2 said:
When you sort the engine breather out make sure it is away from the turbo intake, or it just breathes it's own foul air, and the filter on the turbo could also be a problem, so make sure that it is clean also.
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Thanks for that, it is sited well away from the intake. Filter is brand new, but I may try it without it just in case it's restrictive if the above fixes don't cure the problem.
 
Echo omega2's comment... beware of the engine breathing oily air from the breather, twill clog up the intercooler and prevent full power hence revs down and hence boost down. I ended up piping the breathers into a coelescing (sp?) pot and filtered the air out of it to prevent oily breather air. Worked well.
 
Murv said:
Thanks for that, it seemed unlikely to me but maybe it would benefit from a clean anyway. The old turbo had been spitting oil into the cooler for an unknown amount of time
The prop is loading the engine, max rpm is 4000, it's only achieving 3100. But, it's a big improvement on the 2500 it was making before at 2.5psi.
I need to go over the piperwork again, and check the vacuum tube to the pump. They were OK, but with all the work that's been undertaken, it's possible something has been holed or become loose.
I was just thinking out loud really, where to go from here really if everything checks out OK.
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The oil leak is definitely something which could affect turbo performance as it both causes restrictions in the passageways and effects the rate of heat transfer resulting in hotter air going to the engine.

A clean up of the air cooler should certainly improve matters and there are commercial chemicals available for this however usually sold only in large quantities such as Acc9 Cleaner. However a similar result may be obtained by first removing the oil deposits and muck with something like Paraffin and then finally cleaning with a degreaser to remove the oil film. Possibly others may have found a source for the correct chemicals in small quantities.

This cleaning is best done off the engine or at least ensure nothing passes into the engine.

You did not mention what colour the exhaust is . I would expect it to be discoloured or even black so if it is clear then possibly the fuel boost system is not working!
 
Thank you both, appreciated.

Bilgediver, I'm going to remove it and wash it out with iso-octane. That should clean the oil out without damaging the rubber seals in the end caps, then I can bake it at low temperature to dry it out thoroughly. I was hoping to get new O rings and clean it out properly as per Omega2's post, but I can't find the size of the O rings until it's removed and time is a bit tight as it needs to be back together for my first training session a week today.
I think the exhaust was reasonably clean, but it's had the wrong injectors fitted ever since I bought it so it hasn't been fueling properly ever since I've had it.
Although, the lower fuel volumes may well have suited the reduced output from the damaged turbo!
 
Murv said:
Thanks for that, it is sited well away from the intake. Filter is brand new, but I may try it without it just in case it's restrictive if the above fixes don't cure the problem.
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the intake filter need only be small enough to stop seagulls and rats going through, plus the odd nut and bolt, or in my case a finger LOL take the matrix and get it pressure washed mere soaking will have no effect, you will realise this when you have it out the case, those tubes are well stacked and close together. you can find a number on the case Bowman will then be able to assist you.
 
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omega2 said:
the intake filter need only be small enough to stop seagulls and rats going through, plus the odd nut and bolt, or in my case a finger LOL take the matrix and get it pressure washed mere soaking will have no effect, you will realise this when you have it out the case, those tubes are well stacked and close together. you can find a number on the case Bowman will then be able to assist you.
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Thanks for that, I'll have to do that then. I did try Bowman, but they won't sell to the public (or they will, but it's a minimum order size)
The only information I have off it is that it's an FC3.
It will probably have to be a quick solvent rinse at the weekend, as I say I need it running for Thursday although it doesn't need to be making full power by then.
 
Murv said:
Thanks for that, I'll have to do that then. I did try Bowman, but they won't sell to the public (or they will, but it's a minimum order size)
The only information I have off it is that it's an FC3.
It will probably have to be a quick solvent rinse at the weekend, as I say I need it running for Thursday although it doesn't need to be making full power by then.
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lancing marine will have what you need if you have the number of the part, as you say Bowman have gone snotty this year.
 
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