Intercooler: Service and Repair

1. Determine what type of damage has been done to the charge air cooler.

Part 1:

Part 2:

2. Refer to the Charge Air Cooler Cross-Reference Chart to determine if the damage is repairable and what types can be made.

Crimp Joint Service/Repair

Leak Repairs - Tanks-to-Header
1. Using Leak Test - Charge Air Cooler, identify the area of the leak(s).
2. Mark all of the areas where pressure loss exceeds 1.5 psig per minute.
3. Tighten the crimp tabs in the area(s) of the leak.
4. Leak test the charge air cooler.
5. If the charge air cooler fails the leak test, install a new charge air cooler.

Broken Tabs Causing Leak - Tank-to-Header
1. Tighten crimp tabs nearest to broken tab causing the leak.
2. Leak test the charge air cooler.
3. If the charge air cooler fails the leak test, install a new charge air cooler.

Welding Repairs - Sidemembers
1. All surfaces to be welded must be free of all paint, oil, grease, water and other foreign matter in the area so the weld repair will adhere to the bare aluminum and will not be contaminated.
2. Cut a V-shaped groove along the length of the crack to a depth equal to the member thickness.
3. Weld-fill the groove.
^ Use a suitable MIG welder.

4. Wire brush and grind any excess weld material to provide a flat surface.
5. Clean the charge air cooler.

Welding Repairs - Mounting Brackets
1. All surfaces to be welded must be free of all paint, oil, grease, water and other foreign matter in the area so the weld repair will adhere to the bare aluminum and will not be contaminated.
2. Tack-weld the bracket in place.
^ This will retain the bracket in its correct orientation.
^ Use a suitable MIG welder.

CAUTION: Care must be taken not to melt the fins or the tube-to-header braze joint. If welding near the core, shield the core with a large steel plate. This will protect it from sparks and weld splatter and will act as a heat sink.

3. Weld the bracket in place.
^ Use a suitable MIG welder.

4. Allow the bracket to air-cool.
5. Check the bracket alignment.
6. Clean the charge air cooler.

Welding Repairs - Tubes or Tube Header Joints
1. All surfaces to be welded must be free of all paint, oil, grease, water and other foreign matter in the area so the weld repair will adhere to the bare aluminum and will not be contaminated.
2. Weld the tube or tube header joint.
^ Use a suitable MIG welder.
^ Use Alcan MIG Electrode Wire, 1.20-mm (3/16-inch) diameter, 4043 aluminum alloy, aluminum wire or equivalent.

3. Clean the charge air cooler.

Epoxy Repairs - Tubes or Headers
1. All surfaces to be welded must be free of all paint, oil, grease, water and other foreign matter in the area so the epoxy will adhere to the bare aluminum.
2. Apply epoxy to the damaged tube or header.
^ Use only a high-temperature epoxy.
^ Use resin CIBA GEIGY ARADLITE AV 138M and hardener CIBA GEIGY HV 998 or equivalents.
^ The mix and cure instructions on the products must be strictly adhered to.

3. Clean the charge air cooler.

Cleaning After Weld or Epoxy Repairs - Power Flushing
1. Orient the charge air cooler so that the tank containing the repair or closest to the repair point is at the bottom.
2. Power flush the charge air cooler from the opposite tank at the top.
^ Power flush with water at a rate of 0.06 in (1.5 mm) per second for 3 minutes.

3. Invert the charge air cooler.
4. Power flush the charge air cooler in the opposite direction.
^ Power flush with water at a rate of 1.5 mm (0.06 in) per second for 3 minutes.

5. Drain all of the water from the charge air cooler and allow it to air-dry.
6. Leak test the charge air cooler.

NOTE: A leak test must be performed on all repairs prior to painting or installing the charge air cooler.

Cleaning After Weld or Epoxy Repairs - Alternate Method
1. Lay the charge air cooler flat with the inlet and outlet ports pointing up.
2. Fill the charge air cooler to 40 percent of its volume with water.
3. Agitate the charge air cooler by hand for at least 10 minutes.
4. Drain the water from the charge air cooler.
5. Repeat Steps 1 through 4 until no debris is found in the flushing water.
6. Allow the charge air cooler to air-dry.
7. Leak test the charge air cooler.

NOTE: A leak test must be performed on all repairs prior to painting or installing the charge air cooler.

Leak Test - Charge Air Cooler
1. Install an air pressure gauge in one port of the charge air cooler.

NOTE: To ensure proper performance, all repaired charge air coolers must be leak tested and pressure checked prior to painting or installing into the vehicle.

2. Install a stop/air supply in the other port.
3. Apply 50 psig of air pressure.
4. Reduce air pressure to 29 psig.
5. Let the charge air cooler stand for a few minutes and note any loss in pressure.
^ If the pressure loss exceeds 1.5 psig per minute, repair the leak.

6. Replace the charge air cooler if there is any permanent distortion.