Intercooler: Service and Repair

Charge Air Cooler Repairs






Charge Air Cooler (CAC) Inspection

1. NOTE: If there is any oil residue, clean both connecting ports and the inside of the Charge Air Cooler (CAC) tube to prevent the tube from falling off.

Carefully inspect the CAC, CAC tubes and CAC hoses for holes, tears, cuts, abrasion, oil saturation or sponginess and order only the components needing replacement. Discard all CAC clamps and install new CAC clamps.

2. Determine what type of damage has been done to the CAC. Refer to the following chart to determine the status of the CAC.










Flushing

1. NOTICE: Do not use a high-pressure power washer to clean the Charge Air Cooler (CAC) or damage to the CAC may occur.

NOTE: Drain all contaminates such as coolant, fuel and oil prior to cleaning the CAC.

NOTE: Thoroughly clean the joint clamp areas as well as the turbocharger connection, engine connection and the CAC connections, using metal brake parts cleaner.

Lay the CAC flat with the inlet and outlet ports pointing up.

2. NOTE: Plug or cap the CAC openings prior to agitating.

Add an appropriate amount of a commercially available detergent cleaner such as Simple Green(R) Pro HD, or equivalent, to the CAC. Follow the manufacturer's directions for heavy cleaning. Fill the CAC to 40% of its volume with water.

3. Raise one end of the CAC and agitate it by hand for at least 5 minutes.

4. Raise the other end of the CAC and agitate it in the other direction by hand for at least 5 minutes.

5. Drain the CAC.

6. Flush the CAC thoroughly with clean water.

7. Repeat Steps 1 through 6 until no contaminates are found in the flushing water.

8. Allow the CAC to air-dry.

9. NOTE: A leak test must be performed prior to painting or installing the CAC.

Perform the Leak Test - Charge Air Cooler (CAC).


Leak Test - Charge Air Cooler (CAC)

1. NOTE: Use a commercially available kit, such as the Johnson Manufacturing Company Charge Air Cooler Test Set Part No. 351-CAS, or equivalent.

NOTE: Use a known good hose to adapt the hot side to the Charge Air Cooler Test Plug.

NOTE: Any cleaned or repaired CAC must be leak tested prior to painting or installing into the vehicle.

Install the commercially available CAC tester on the CAC, following the manufacturer's installation instructions.
- Tighten the clamps to 12 Nm (106 lb-in).

2. WARNING: Never exceed the specified pressure. Excessive pressure may cause the test adapter to blow off or may damage the charge air cooler (CAC). Failure to follow this instruction may result in serious personal injury.

Slowly apply air pressure to 207 kPa (30 psi).

3. Let the CAC stand for a few minutes and note any loss in pressure.
- Release the air pressure.

4. Repeat Steps 2 and 3 as many times as necessary to verify the readings. The reading is considered verified when 3 consecutive tests show approximately the same pressure drop.
- If the pressure loss exceeds 10 kPa (1.5 psi) per minute, install a new CAC. For additional information, refer to Charge Air Cooler - 6.0L Diesel .