Service Manual

ISB, ISBe and QSB (Common Rail [...] Charge-Air Cooler (CAC)
Section 10 - Air Intake System - Group 10 Page 10-25
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Initial Check
Inspect the charge air cooler for cracks, holes, and
damage.
Inspect the tubes, fins, and welds for tears, breaks, or
other damage.
If any damage causes the charge air cooler to fail the air
leak check, the charge air cooler must be replaced.
Inspect the charge air cooler plumbing for cracks and
damage.
Remove
Remove the charge air cooler. Refer to the OEM service
manual.
Clean
NOTE: If the engine experiences a turbocharger failure or
any other occasion where oil or debris is put into the
charge air cooler, the charge air cooler must be cleaned.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of 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 (i.e., the water runs clear).
NOTE: Make sure that 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.