NHTSA ID Number: 10131153
Manufacturer Communication Number: IK0900064
TSB/Document Date: 2018-04-02
Summary
Charge Air Cooler (CAC) Leak Test (Air Decay test); only vehicles whose ewngines are equipped with charge air coolers.
IK0900064 - Charge Air Cooler (CAC) Leak Test (Air Decay test)
Countries:
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AUSTRALIA, BRAZIL,
CANADA, UNITED
Document
IK0900064
STATES, MEXICO,
ID:
SOUTH AFRICA
Availability: ISIS
Major
COOLING
System:
Revision:
3
Created:
6/5/2012
Current
English
Language:
Other
NONE
Languages:
Last
Modified:
10/3/2013
Author:
Thomas
Hoffmeister
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1785
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Title: Charge Air Cooler (CAC) Leak Test (Air Decay test)
Applies To: All Charge Air Coolers
DESCRIPTION
Charge Air Cooler (CAC) Testing
RESOLUTION
NOTE: Always adhere to the Safety Warnings and Instructions included in the CAC test
kit. Charge Air Cooler (CAC) Pressure Decay Test
1. Remove CAC piping from the turbocharger and engine air inlet connections. The CAC can
remain in the chassis for this test. Existing hump hoses and clamps on the CAC itself will be
used for this test. Double clamp all hump hose connections and tighten all constant torque
clamps to 105 in-lbs.
2. Using CAC test kit ZTSE-4341, insert proper size plug in the hose ends and tighten clamps
to 105 in-lbs.
3. Double check all connections to verify that all joints are tight. Close air pressure regulator
and drain valve before beginning test.
4. Begin test by slowly opening air pressure regulator until test pressure reaches 30 psi. When
30 psi test pressure is reached, close the shut-off valve.
5. Monitor pressure gauge and determine rate of pressure decay with a stopwatch. If pressure
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IK0900064 - Charge Air Cooler (CAC) Leak Test (Air Decay test)
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drop exceeds 5 psi in 15 seconds, recheck all connections.
6. If a leaking connection is found, tighten the connection and conduct three consecutive
tests to verify the reading.
7. After testing, open the drain valve to release pressure .
8. If pressure decay does not exceed 5 psi in 15 seconds, the CAC system is within
acceptable performance limits.
9. If the CAC assy pressure decay does not exceed 5 psi in 15 seconds, the CAC assy
is within acceptable performance limits and should not be replaced. If the CAC fails the
pressure decay test, replace the CAC and document the pressure drop on the warranty
claim.
10.Remove testing equipment and re-install CAC hoses and pipes. Torque the constant torque
clamps to 105 in-lbs.
OTHER RESOURCES
• Warranty Policy Letter WPL2800009
• CAC Test kit ZTSE-4341 is available in through the Tool Catalog
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Copyright © 2013 Navistar
, Inc.
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TSB/Document ID: IK0900064
Replacement Service Bulletin Number:
MFR Communication Date: 2013-10-03
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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