Procedures

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 from the vehicle. For additional information, refer to Charge Air Cooler - 6.7L Diesel Removal and Replacement.

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.

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. These may be signs of misuse and could void the warranty. If these are found, flush the cooler, refer to Flushing in this procedure.

Vehicles Without Turbocharger Failure

1. If there is no turbocharger problem, but oil is found dripping from the CAC tubes or joints, remove the lower end of the cold CAC 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 tube.

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

Flushing

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

NOTE: Drain all contaminants 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 contaminants are found in the flushing water.

8. Allow the CAC to air dry.

9. Install the CAC. For additional information, refer to Charge Air Cooler - 6.7L Diesel Removal and Replacement.