Charge Air Cooler (CAC) Cleaning

Charge Air Cooler (CAC) Cleaning





Charge Air Cooler (CAC) Inspection

Vehicles With Turbocharger Failure

1. If there has been metal contact within the turbocharger compressor:
1. Remove the Charge Air Cooler (CAC) tubes and inspect for metal particles.

2. Remove the CAC (Charge Air Cooler) from the vehicle. For additional information, refer to Charge Air Cooler- 6.7L Diesel .

3. Blow shop air into the hot air port (angled port) to dislodge metal particles from the heat exchanger core, being careful to observe any metal particles coming out.

4. If metal particles are found, install a new CAC (Charge Air Cooler).

2. Drain the fluids by tilting the ports downward and rocking the cooler to fully drain each port.

3. Inspect for any burnt-on oil or dust collected on the CAC (Charge Air Cooler). These may be signs of misuse and could void the warranty. If these are found, flush the cooler, refer to Flushing.

Vehicles Without Turbocharger Failure

1. If there is no turbocharger problem, but oil is found dripping from the CAC (Charge Air Cooler) tubes or joints, remove the lower end of the cold CAC (Charge Air Cooler) tube, and collect and properly dispose of any oil that spills out.
- If oil drains out, find source of the oil by investigation of the turbocharger or crankcase ventilation system. With the vehicle on level ground, drain the oil that spills out and reinstall the CAC (Charge Air Cooler) tube.

- If no oil drains out, reinstall the CAC (Charge Air Cooler) tube. In this case, no further action is needed for the CAC (Charge Air Cooler).


Flushing

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

NOTE: Drain all contaminants such as coolant, fuel and oil prior to cleaning the CAC (Charge Air Cooler).

NOTE: Thoroughly clean the joint clamp areas as well as the turbocharger connection, engine connection and the CAC (Charge Air Cooler) connections, using metal brake parts cleaner.
Lay the CAC (Charge Air Cooler) flat with the inlet and outlet ports pointing up.

2. NOTE: Plug or cap the CAC (Charge Air Cooler) 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 (Charge Air Cooler). Follow the manufacturer's directions for heavy cleaning. Fill the CAC (Charge Air Cooler) to 40% of its volume with water.

3. Raise one end of the CAC (Charge Air Cooler) and agitate it by hand for at least 5 minutes.

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

5. Drain the CAC (Charge Air Cooler).

6. Flush the CAC (Charge Air Cooler) thoroughly with clean water.

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

8. Allow the CAC (Charge Air Cooler) to air dry.

9. Install the CAC (Charge Air Cooler). For additional information, refer to Charge Air Cooler- 6.7L Diesel .