IK1201175 ­ Charge Air Cooler Cleaning Procedure for I-6, V­6 & V­8 Engines

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Title : Charge Air Cooler Cleaning Procedure for I-6, V-6 & V-8 Engines
Applies To : All MaxxForce DT, 9, 10, V-6 & V-8 Engines

CHANGE LOG
08/21/2014 Initial article release.
10/01/2014 Update note & image to not clean CAC's that have a sharp bend on vehicle.

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Subject: Charge Air Cooler Cleaning Procedure
Model: ALL
Engine Family: MaxxForce DT, 9, 10, V-6 & V-8 Engines
DESCRIPTION
The following procedure demonstrates cleaning High Pressure (vehicle mounted) CACs on vehicle utilizing the Cleaning
Management System (CMS), CAC Pressure Test Kit, and new CAC Adapter Flushing Kit.
PARTS INFORMATION
Table 1. Tools Information.
Description

Tool Number / Type

Cleaning Management System (CMS)

12­353­01

Charge Air Cooler (CAC) Adapter Flushing Kit

09­925­01

Charge Air Cooler (CAC) Pressure Test Kit

ZTSE 4341

Table 2. Parts Information.
Part Number
2512460C1

Description
Fluid, EGR Cleaning

Quantity
5 gal

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IK1201175 ­ Charge Air Cooler Cleaning Procedure for I-6, V­6 & V­8 Engines

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SERVICE PROCEDURE PREPARATION

NOTE: This procedure applies to High Pressure (HP) Charge Air Coolers (CAC) only.
NOTE: Some vehicles have Charge Air Coolers (CAC) with a sharp bend on the inlet/outlet as shown below. This can
allow fluid to become trapped during cleaning on vehicle. Units with this type of configuration should have the
CAC removed for cleaning. Use the procedure below on vehicles with horizontal inlets/outlets only.

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IK1201175 ­ Charge Air Cooler Cleaning Procedure for I-6, V­6 & V­8 Engines

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IK1201175 ­ Charge Air Cooler Cleaning Procedure for I-6, V­6 & V­8 Engines

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ON VEHICLE PRESSURE TEST
1. Bring vehicle into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking brake, and install wheel chocks.
3. Unlatch and open hood.

NOTE: CACs are not required to be leak proof. Do NOT test CAC for leakage by submerging it in a radiator test tank.
Almost all CACs will show leakage if they are submerged.

1. Install CAC Pressure Test Kit per instructions included with ZTSE4341, using appropriate hoses and clamps from CAC
Adapter Flushing Kit 09-925-01.

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IK1201175 ­ Charge Air Cooler Cleaning Procedure for I-6, V­6 & V­8 Engines

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2. Connect a filtered air supply to air valve (Figure 1, Item 3) on gauge / regulator assembly.

3.Open air valve (Figure 1, Item 3) slightly, and slowly increase air pressure until gauge (Figure 1, Item 1) reads 30 psi (205 kPa).
If required, adjust air regulator (Figure 1, Item 2) until gauge reads 30 psi (205 kPa) as follows:
A. Pull air regulator knob (Figure 1, Item 2) outward to unlock.
B. Turn air regulator knob (Figure 1, Item 2) to adjust pressure to 28 - 32 psi (193 - 221kPa).
C. Push air regulator knob (Figure 1, Item 2) back into locked position.
4. Close air valve (Figure 1, Item 3) and monitor gauge (Figure 1, Item 1) with stop watch for 15 seconds. Note any decrease in air
pressure.
5. Repeat Steps 3 and 4 three times to verify results.

Figure 2. Bleeding Air Pressure.
1. Bleed-off coupler
2. Adaptor hose

6. If air pressure drop is more than 5 psi (34 kPa) in 15 seconds, replace CAC. If air pressure drop is 5 psi (34 kPa) or less in 15
seconds, perform cleaning procedure.
7. Slowly turn bleed-off valve (Figure 2, Item 2) on bleed-off coupler (Figure 2, Item 1) counterclockwise and release air from
system.
8. Disconnect filtered air supply from air valve.

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9. Remove CAC Pressure Test Kit per instructions included with ZTSE 4341.

CLEANING PROCEDURE
1. Make sure reservoir of Cleaning Management System (CMS) is clean and filter has been replaced.
2. Add 5 gallons (18.93 liters) of tap water to CMS reservoir first, followed by 5 gallons (18.93 liters) of cleaning fluid.
3. Position PUMP / HEATER switch on CMS to HEATER and allow temperature to reach approximately 130°F (54.44°C) before
flushing.
4. Install CAC Adapter Flushing Kit per instructions included with 09­925­01.

Figure 3. Outlet Adapter.
1. CMS FLOW FROM PUMP hose
2. Outlet adapter
5. Connect CMS FLOW FROM PUMP hose (Figure 3, Item 1) to outlet adapter (Figure 3, Item 2).

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Figure 4. Inlet Adapter.
1. Inlet adapter
2. CMS FLOW RETURN hose
6. Connect CMS FLOW RETURN hose (Figure 4, Item 2) to inlet adapter (Figure 4, Item 1).
7. Set and start timer on CMS for 20 minutes, position PUMP / HEATER switch on CMS to PUMP, and perform 20-minute backflush.
8. Position PUMP / HEATER switch on CMS to OFF.
9. Disconnect CMS FLOW RETURN hose (Figure 4, Item 2) from inlet adapter (Figure 4, Item 1).
10. Disconnect CMS FLOW FROM PUMP hose (Figure 3, Item 1) from outlet adapter (Figure 3, Item 2).
11. Connect CMS FLOW RETURN hose to outlet adapter.
12. Connect CMS FLOW FROM PUMP hose to inlet adapter.
13. Set and start timer on CMS for 20 minutes, position PUMP / HEATER switch on CMS to PUMP, and perform 20-minute
forward­flush.
14. Position PUMP / HEATER switch on CMS to OFF.
15. Disconnect CMS FLOW FROM PUMP hose from inlet adapter.
16. Disconnect CMS FLOW RETURN hose from outlet adapter.
17. Drain and clean CMS.
18. Fill CMS with 10 gallons of hot tap water.
19. Connect CMS FLOW FROM PUMP hose to outlet adapter.
20. Connect CMS FLOW RETURN hose to inlet adapter.
21. Set and start timer on CMS for 10 minutes, position PUMP / HEATER switch on CMS to PUMP, and perform 10-minute rinse
with hot tap water.
22. Position PUMP / HEATER switch on CMS to OFF.
23. Disconnect CMS FLOW FROM PUMP hose from outlet adapter.

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24. Disconnect CMS FLOW RETURN hose from inlet adapter.
25. Blow dry CAC with compressed air.
26. Drain and clean CMS.
27. Fill CMS with 10 gallons of tap water.
28. Connect CMS FLOW FROM PUMP hose to inlet adapter.
29. Connect CMS FLOW RETURN hose to outlet adapter.
30. Set and start timer on CMS for 10 minutes, position PUMP / HEATER switch on CMS to PUMP, and perform 10-minute rinse
with hot tap water (cold water is sufficient if hot tap water is not available).
31. Position PUMP / HEATER switch on CMS to OFF.
32. Disconnect CMS FLOW FROM PUMP hose from inlet adapter.
33. Disconnect CMS FLOW RETURN hose from outlet adapter.
34. Remove CAC Adapter Flushing Kit per instructions included with 09­925­01.
35. Drain and clean CMS.
36. Blow dry CAC with compressed air.

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 09046 - Cooling
Noun:

925 - Charge Air Cooler, Chassis Mounted

Standard Repair Time(s):
Description
CAC Cleaning, Perform

Chassis
All Models

Engine
All Engines

SRT
Hours
A09­3925A 1.1

SERVICE PROCEDURE FOLLOW-UP
1. Run engine to verify proper operation, no leaks, and no fault codes.
2. Close and latch hood.
3. Remove wheel chocks.

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Copyright © 2014 Navistar, Inc.

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