Bruce Amacker Posted July 31, 2009 Share Posted July 31, 2009 Well, I finally got around to cutting open the cooler and shooting some pics of it. The port on the right with the protrusion is a coolant port, the left side port is an oil port. The cooler was cut with a bandsaw on the short side and cleaned in a bead blast tank, no other prep was done. The camera is an Olympus E-300 8mp with a Zuiko 1:3.5 35mm macro lens. I don't know what the manufacturing process is, maybe sonic welding or something? I believe it is assembled in layers of plates like a sandwich, one layer at a time. There are fins present in both the oil side and coolant side of the cooler, which is why these units cannot be cleaned. They act as a "filter" of sorts, trapping crud that makes it past the filter on the oil side, and trapping cooling system crud and casting leftovers on the coolant side. The reason there's crud on the oil side is because the oil filter runs in bypass mode when the oil is cold, so not all oil is filtered. I should send this thing to Damon for shots, as he's become somewhat of a macro photographer guru lately, taking great shots of things up close. Quote Link to comment Share on other sites More sharing options...
Aaron Posted July 31, 2009 Share Posted July 31, 2009 Cool! (No pun, yadda...) You guys must go through a lot of bandsaw blades over there Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted July 31, 2009 Share Posted July 31, 2009 I knew if I dropped the bait Bruce would bite. Boy, I have to wonder if a cutaway oil cooler would reveal anything visible to show what is happening with them. Oustanding Bruce! Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted July 31, 2009 Author Share Posted July 31, 2009 I knew if I dropped the bait Bruce would bite. Yep, a sucker I is. Boy' date=' I have to wonder if a cutaway oil cooler would reveal anything visible to show what is happening with them. [/quote'] I'm going to guess the failures come from the round circular area in the second pic where the plates are "welded" or fused together. It almost appears from the pic the seam is not 100% perfect from the factory, and this was not even a leaking cooler. It was done as a maintenance gig while the top of the motor was off with 150K or so. Complaint was an oil leak from the top, but the owner (wisely) knows 6.0 pattern failures and changed both coolers and several small things, along with a turbo recon while it was apart (on my suggestion). Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted July 31, 2009 Share Posted July 31, 2009 I am more interested in the build up of crud on the coolant side which I attribute to the overheating and failure of EGR coolers. FYI you are my favorite sucker. Quote Link to comment Share on other sites More sharing options...
Aaron Posted August 2, 2009 Share Posted August 2, 2009 I am more interested in the build up of crud on the coolant side which I attribute to the overheating and failure of EGR coolers I ran one in the parts washer (varsol hose on the coolant inlet) for a week, and NONE of that sludgy shit came out of it. Quote Link to comment Share on other sites More sharing options...
cbriggs Posted August 4, 2009 Share Posted August 4, 2009 I just pulled one that is plugged right to the top of the coolant inlet port. Another dealer changed an egr cooler, lasted 1500 kms and puked again.Customer called headgaskets, but I suspected oil cooler so i pulled it, and found it completely plugged. I have plans to cut it open as well, when i can find time. Now it needs 8 injectors because of the water in engine,( twice in one week probly doesnt help either) test drove it 20km, ran good. 3 days later customer picked up, drove 40 kms and started missing, now doesn't start at all. Quote Link to comment Share on other sites More sharing options...
Brad Clayton Posted August 4, 2009 Share Posted August 4, 2009 Quote: Now it needs 8 injectors because of the water in engine Is that due to an after axle tank, or did they pay $3 bucks a gallon for high quality H2O? Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted August 4, 2009 Author Share Posted August 4, 2009 Here's a couple of more pics, too bad this cooler wasn't clogged with crap. If anyone has a clogged cooler and wants to donate it, I'll pay shipping to get it here and then cut it open. Quote Link to comment Share on other sites More sharing options...
Aaron Posted August 6, 2009 Share Posted August 6, 2009 I'd ship, i've got a couple - but wouldn't it be considered 'hazardous goods'? Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted August 6, 2009 Author Share Posted August 6, 2009 It shouldn't be "hazardous goods" unless it has oil or flammable liquids in it. Drain it (them) well, dry it off externally, and wrap in plastic so it doesn't seep, and box it. It should be good to go. Do you have one or more that's visibly plugged, or you knew from ECT/EOT? I'd be happy to reimburse you postage plus lunch on anything you send. I can mail a check or use PayPal if that's better. I'll PM you my address. Note to self: Buy more bandsaw blades..... Thanks! PS On edit: I'll be at Woodward Dream Cruise next Fri/Sat, usually around 12-13mi roads. Are you going to be there by chance? Anyone else? Quote Link to comment Share on other sites More sharing options...
eastendpowerstroke Posted August 6, 2009 Share Posted August 6, 2009 I think I got one around Bruce I'll look tomorow. If I do I'll throw it in one of those USPS flat rate boxes and mail it to ya. Quote Link to comment Share on other sites More sharing options...
cbriggs Posted August 6, 2009 Share Posted August 6, 2009 Quote: Is that due to an after axle tank, or did they pay $3 bucks a gallon for high quality H2O No, its actually caused by water in the oil from a bad egr cooler failure (or 2 back to back as in this case) This is actually the second time i have seen this. Just hung 8 injectors and rechanged the oil ( i also did it when egr cooler and oil cooler replaced) Runs good now. Quote Link to comment Share on other sites More sharing options...
Damon Posted August 14, 2009 Share Posted August 14, 2009 I am more interested in the build up of crud on the coolant side which I attribute to the overheating and failure of EGR coolers. I haven't gotten to cut apart a clogged one, but I did get pics and got the stuff back out and dried it out to see what it was. It took several days to do.... Here's the cooler as removed: And the condensed sludge: And the sludge dried: That's all it takes to clog one of these. Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted August 14, 2009 Share Posted August 14, 2009 PS On edit: I'll be at Woodward Dream Cruise next Fri/Sat, usually around 12-13mi roads. Are you going to be there by chance? Anyone else? Are you bringing that SWEET Vette of yours? 12-13 Mile where at? Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted August 14, 2009 Author Share Posted August 14, 2009 Are you bringing that SWEET Vette of yours? 12-13 Mile where at? No, this year we're bringing my brother-in-law's '67 Vette. We took mine the last couple of years. It's just as nice, or nicer, than mine- high option car, original (nice!) paint, bolt-ons, sunburst yellow coupe. I'll have my cell which forwards from my business line, 440-846-3885 if you want to hook up. We're staying at the Embassy Suites in Troy tonight, so we'll be there this evening on the strip, too. Is 75 still closed? Here's a shot from WWDC last year- we drove the Vette, and I ended up buying the Ghia, which is body-off restored and beautiful! I've always liked old VW's and had a bunch when I was a kid. The weather's supposed to be great, I'm looking forward to it. Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted August 14, 2009 Author Share Posted August 14, 2009 Nice pics, Damon! You want me to cut that one apart? Quote Link to comment Share on other sites More sharing options...
mchan68 Posted August 14, 2009 Share Posted August 14, 2009 I'll be at Woodward Dream Cruise next Fri/Sat, usually around 12-13mi roads. Are you going to be there by chance? Anyone else? Damn I miss going to Michigan for my "vacations". Ever since my aunt left Northville after living in Michigan for over 40 years to retire in Hawaii in 2001, I haven't had any reason to return there. I STILL remember how easy it was to navigate through all the "Mile Roads" that run east and west. I still probably remember most of the major roads (Telegraph, Middlebelt, Inkster, West Grand Rapids, etc.). Quote Link to comment Share on other sites More sharing options...
Bruce Amacker Posted August 14, 2009 Author Share Posted August 14, 2009 So come on down tomorrow and make a day trip out of it, I'd like to meet you! The weather's supposed to be hot and clear, perfect for a car show. The manufacturers (usually!) set up big exhibits with concept cars, there's free bands playing on stages in the open, a true carnival atmosphere! Even the Navy got involved a couple of years ago with an A-10 Warthog coming down for a low flyover and full throttle vertical climb over Woodward that drowned out ALL noise for 30 seconds or so. There's more weird cars on Woodward tomorrow than you'd ever dream- 40,000 classic cars and 1.7 million people were forecast last year. I tried counting them but....... Quote Link to comment Share on other sites More sharing options...
Jim Warman Posted August 14, 2009 Share Posted August 14, 2009 In a public forum, there was a discussion on coolant filters for the 6.0. Some wit remarked that the 6.0 already has a coolant filter situated beneath the oil filter.... Bruces pics illustrate that there is some truth to that. A note on 'joinery'... how some assemblies are turned from parts into assemblies.... Many years ago, Convair developed the B58 'Hustler' - a delta wing, supersonic bomber - for the US air force (I was a 'things with wings" kinda kid). One of many technological advances for this airplane was the use of adhesives instead of rivets for many components. Even today, where composites and chemicals and adhesives constitute such a remarkable component of modern aviation (and let's not forget that the space shuttles tiles are "glued" on), this old fart has a timne wrapping his head around the concept at times... Now... take a look around your house.... some of your furniture has, more likely than not, been assembled using an adhesive that is activated using either high frequency radio waves or perhaps even microwaves (which are nothing more than extremely high frequency radio waves). The engineers are constantly dreaming up new and intriguing ways to fullfil old (and some not so old) requirements. Thinking of the Ecoboost and the Scorpion sends a cold shiver up my spine. Quote Link to comment Share on other sites More sharing options...
LARRY BRUDZYNSKI Posted August 14, 2009 Share Posted August 14, 2009 West Grand Rapids, etc.). Mike I think you mean West Grand Blvd. You were in Northville????Did you ever go to Northville Downs???? Were you there for any amount of time? If you were you probably dealt with the local NAPA, B&F auto supply. Quote Link to comment Share on other sites More sharing options...
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