Clean the Aftercooler Core and Inspect the Aftercooler Core
Inspect the following parts at each oil change:
- Hoses
- Hose clamps
- Gasket joints
- Remove the aftercooler core from the housing. Refer to Disassembly and Assembly Manual, "Aftercooler - Remove" for the complete procedure.
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Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.
Show/hide tableNOTICE Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the core and cause leakage.
- Use hot, soapy water to clean the aftercooler core. Allow the excess soapy water to drain. Blow dry the fins with compressed air.
- Flush the inside of the core in the reverse direction of flow. Use hot, soapy water. Thoroughly rinse the core with clean water.
- Thoroughly clean the internal surfaces and external surfaces of the aftercooler housing.
- Inspect the front and the rear of the aftercooler housing for cracks and distortion.
- Inspect the aftercooler core for signs of leakage, cracks, and damaged fins.
- Pressure test the aftercooler core. Refer to "Clean the Aftercooler Core and Inspect the Aftercooler Core".
| Tools Needed | ||
| Part Number | Part Name | Quantity |
| 1U-5470 | Engine Pressure Group | 1 |
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| Illustration 1 | g00764460 |
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(1) Safety chain
(2) Typical example of the aftercooler core (3) Outlet (4) Inlet (5) Plug with compressed air valve (6) Valve for compressed air (7) Plug | |
- Install plug (7) to the outlet (3) of the core. Secure the hose clamps and install safety chains. This will prevent the release of the plug if the hose clamps fail to hold the plug under pressure.
- Install plug (5) to the inlet (4) that has a compressed air valve. Tighten the hose clamps and install safety chains. This will prevent the release of the plug if the hose clamps fail to hold the plug under pressure.
- Install a regulated air supply to the valve for compressed air (5).
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Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.
Show/hide tableNOTICE Do not use more than
240 kPa (35 psi) of air pressure or damage to the aftercooler core can be the result. - Apply
220 kPa (32 psi) of pressurized air to the core. - While the core is still under pressure, completely submerge the core in a tank of water for at least one minute. Check for signs of leakage.
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To help prevent personal injury when the tooling is removed, relieve all pressure in the system slowly by using an air regulator and a valve assembly.
- Remove the core from the tank of water. Slowly relieve the air pressure until the air pressure is zero.
- If the core leaked, replace the seals. Check the core for signs of corrosion. Retest the core after the seals have been replaced. If the core still leaks, the core will need to be replaced.
- Install the aftercooler core. Refer to Disassembly and Assembly Manual, "Aftercooler - Install" for the correct procedure.
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Dust plug chains must be installed to the aftercooler core or to the radiator brackets to prevent possible injury while you are testing. Do not stand in front of the dust plugs while you are testing. |
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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than |
| NOTICE |
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Do not use caustic cleaners to clean the core. Caustic cleaners can attack the internal metals of the core and cause leakage. |
If a turbocharger failure occurs, remove the aftercooler core. Internally flush the aftercooler core with a solvent that removes oil and other foreign substances. Shake the aftercooler core in order to eliminate any trapped debris. Wash the aftercooler with hot, soapy water. Thoroughly rinse the aftercooler with clean water and blow dry the aftercooler with compressed air. Blow dry the assembly in the reverse direction of normal air flow. To make sure that the whole system is clean, carefully inspect the system.