Troubleshooting Common Problems
| Problem | Symptom | Likely Cause | Solution |
| External Clogging | High oil temp (air-cooled), reduced efficiency. | Dirt, bugs, debris on fins. | Clean exterior as described above. |
| Internal Clogging | High oil temp, low oil pressure, overheating. | Sludge, carbon deposits, old broken-down oil. | Flush internally or replace cooler. |
| Leaking Externally | Visible oil on cooler body or fittings. | Physical damage, cracked weld, loose fitting. | Repair if possible, often requires replacement. |
| Leaking Internally | Oil in coolant, coolant in oil, milky residue. | Failed internal seal or gasket (water-cooled type). | Replace the cooler immediately. Do not run the engine. |
| Damaged Fins | Reduced cooling efficiency. | Impact from debris, corrosion. | Straighten fins with a fin comb. If severe, replace. |
When to Replace vs. Clean
- Clean: If the cooler is only mildly dirty or clogged, and is structurally sound with no leaks.
- Replace: If the cooler has significant physical damage (cracked tanks, severely crushed core), internal leaks (oil/coolant mixing), or is so badly clogged that cleaning is not effective. The cost of a failure is often much higher than the cost of a new cooler.
Preventative Maintenance Schedule
- Every Wash/Service: Visually inspect the cooler for damage and debris.
- Every Oil Change: Monitor oil quality. If the oil becomes dirty very quickly, it could indicate a problem upstream or a dirty cooler shedding contaminant.
- As Recommended: Follow the manufacturer’s specific service intervals for inspection and cleaning. This is often around major service intervals (e.g., every 2-3 years or a certain number of operating hours).