Intercooler: Service and Repair

CHARGE AIR COOLER AND PLUMBING

REMOVAL

WARNING: IF THE ENGINE WAS JUST TURNED OFF, THE AIR INTAKE SYSTEM TUBES MAY BE HOT.

1. Disconnect the battery negative cables.
2. Discharge the A/C system and remove the A/C condenser (if A/C equipped).
3. Remove the transmission auxiliary cooler.





4. Remove the boost tubes from the charge air cooler (Fig. 24).
5. Remove the charge air cooler bolts. Pivot the charge air cooler forward and up to remove.

CLEANING

CAUTION: Do not use caustic cleaners to clean the charge air cooler. Damage to the charge air cooler will result.

NOTE: If internal debris cannot be removed from the cooler, the charge air cooler MUST be replaced.

1. If the engine experiences a turbocharger failure or any other situation where oil or debris get into the charge air cooler, the charge air cooler must be cleaned internally.
2. Position the charge air cooler so the inlet and outlet tubes are vertical.
3. Flush the cooler internally with solvent in the direction opposite of normal air flow.
4. Shake the cooler and lightly tap on the end tanks with a rubber mallet to dislodge trapped debris.
5. Continue flushing until all debris or oil are removed.
6. Rinse the cooler with hot soapy water to remove any remaining solvent.
7. Rinse thoroughly with clean water and blow dry with compressed air.

INSPECTION
Visually inspect the charge air cooler for cracks, holes, or damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. Replace the charge air cooler if damage is found.

Pressure test the charge air cooler, using Charge Air Cooler Tester Kit # 3824556. This kit is available through Cummings Service Products. Instructions are provided with the kit.

INSTALLATION
1. Position the charge air cooler. Install the bolts and tighten to 2 Nm (17 in. lbs.) torque.
2. Install the air intake system tubes to the charge air cooler. With the clamps in position, tighten the clamps to 11 Nm (95 in. lbs.) torque.
3. Install the transmission auxiliary cooler (if equipped).
4. Install the A/C condenser (if A/C equipped). Recharge A/C system.
5. Connect the battery negative cables.
6. Start engine and check for boost system leaks.