Intercooler: Service and Repair

Charge Air Cooler (CAC) Cleaning





Charge Air Cooler (CAC) Cleaning

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

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

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 commercially available detergent cleaner such as Simple Green Pro HD, or equivalent to the CAC (Charge Air Cooler). Follow the manufacturer's directions for 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 opposite end of the CAC (Charge Air Cooler) and agitate it 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 contaminates are found in the flush water.

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

9. NOTE: The following leak test steps must by performed prior to installing the CAC (Charge Air Cooler).

Install the CAC (Charge Air Cooler) Y-pipe, gasket and bolts.

- To install, tighten to 8 Nm (71 lb-in).


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

Install the commercially available CAC (Charge Air Cooler) cooler tester on the CAC (Charge Air Cooler) following the manufacturer's installation instructions.

- Tighten the clamps to 5 Nm (44 lb-in).


11. 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 150 kPa (22 psi).


12. Let the CAC (Charge Air Cooler) stand for a few minutes and note any loss in pressure.
- Release the air pressure.


13. Repeat Steps 11 and 12 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 (Charge Air Cooler). For additional information, refer to Charge Air Cooler .