If the engine experiences a turbocharger malfunction, or any other occasion where oil or debris is put into the charge-air cooler, the charge-air cooler must be cleaned.
Remove the charge-air cooler piping and charge-air cooler from the vehicle. Refer to the OEM service manual.
Use protective caps from the Air Handling Clean Care Kit, Part Number 4919588, to cover open points on the plumbing and engine.
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.
CAUTION
Do not use caustic cleaners to clean the charge-air cooler. Damage to the charge-air cooler will result.
Flush the charge-air cooler internally with solvent in the opposite direction of normal airflow. Shake the charge-air cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris. Continue flushing until all debris or oil is removed.
NOTE: Make sure the tubes are in the vertical direction when flushing.
If the debris can not be totally removed from the charge-air cooler, the charge-air cooler must be replaced.
Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.
CAUTION
The charge-air cooler must be rinsed, dried, and free of solvent, oil, and debris or engine damage will result.
After the charge-air cooler has been thoroughly cleaned of all oil and debris with solvent, wash the charge-air cooler internally with hot soapy water to remove the remaining solvent. Rinse thoroughly with clean water.
Blow compressed air through the inside of the charge-air cooler in the opposite direction of normal air flow until the charge-air cooler is dry internally.
Use protective caps from the Air Handling Clean Care Kit, Part Number 4919588, to cover open points on the charge-air cooler after cleaning.
Inspect the charge-air cooler for cracks, holes, or other damage.
Inspect the tubes, fins, and welds for tears, breaks, or other damage. If any damage causes the charge-air cooler to not pass the air leak test, the charge-air cooler must be replaced.
To check the charge-air cooler for cracked tubes or header, remove the inlet and outlet hoses from the charge-air cooler. The charge-air cooler does not have to be removed from the chassis.
To prevent possible injury if either plug blows off during the test, secure safety chains on the test plugs to any convenient capscrew on the radiator assembly. This test must not be performed without securely fastened safety chains.
Install the charge-air cooler tester, Part Number 3824556.
Apply 207 kPa [30 psi] of air pressure to the charge-air cooler. Close the air pressure regulator.
Determine if pressure decay is caused by a leak in the charge-air cooler or from a leaky connection. Use a spray bottle filled with soapy water and apply the solution to all hose connections. Watch for bubbles to appear, indicating the location of a leak.
If the pressure decay is caused by a leaky connection, repair the connection and repeat the test. If the leak is within the charge-air cooler, repeat the test to verify the accuracy of the pressure decay measurement. Similar pressure decay readings must be obtained in at least three consecutive tests before the reading can be considered accurate.
Monitor the pressure gauge and determine the rate of pressure decay with a stopwatch.
Charge-Air Cooler Pressure Drop
kpa
psi
49
MAX
5
If the pressure drop is greater than the specification listed, the charge-air cooler must be replaced.
Refer to the OEM service manual for replacement instructions.
NOTE: If a charge-air cooler leaks more than 35 kPa [5 psi] in 15 seconds, it will appear as a major leak in a leak tank.
NOTE: Charge-air coolers are not designed to be 100-percent leak-free. If the pressure decay is less than 35 kPa [5 psi] in 15 seconds, the charge-air cooler does not need to be replaced.
Inspect the charge-air cooler fins for obstructions to airflow. Remove obstructions such as a winterfront or debris. Manually lock the shutters, if equipped, in the OPEN position.
If the temperature differential is greater than the specifications, check the charge-air cooler for dirt and debris on the fins and clean as necessary. If the problem still exists, check the charge-air cooler for debris in the fins or between the charge-air cooler and the radiator. Confirm full fan engagement.
Operate the engine at the maximum advertised horsepower and correlating rpm. Record the readings on the manometer.
Charge-Air Cooler System Differential Pressure
mm-hg
in-hg
152
MAX
6
Charge-Air Cooler System Differential Pressure
kpa
psi
21
MAX
3
If the differential pressure is greater than the specification, check the charge-air cooler and associated piping for plugging. Clean or replace if necessary.
If a malfunction resulted in coolant, oil, excessive fuel or excessive black smoke entering the exhaust system, the aftertreatment system must be inspected. Refer to Procedure 014-013 in Section 14.