TSI-13-12-17R1 - Charge Air Cooler Cleaning Procedure - Preparation and Off Vehicle Pressure Test

Sep 27, 2026

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Technical Service Information TSI-13-12-17R1 details a charge air cooler (CAC) cleaning procedure for engines with internal contamination, using a bench workflow with the Cleaning Management System (CMS), a CAC Pressure Test Kit, and a new CAC Adapter Flushing Kit. It specifies required tools and parts, including EGR cleaning fluid, and provides service procedure preparation steps with compliance guidance for handling engine fluids and contaminated materials. It also outlines safety warnings and the off-vehicle pressure test requirements before further service.

LanguageEnglish

CategoryTechnology

FormatPDF

Pages10

Reading Time25 min

AccessFree to download

Service Procedure Preparation

Parts and Tools Information

Government Regulation and Warnings

Vehicle Preparation Steps

Off Vehicle Pressure Test

Inspection and Test Kit Setup

Safety Notes and Test Limitations

Technical Service Information TSI–13–12–17R1 Date: NOVEMBER 2013 Subject File: ENGINE Subject: Charge Air Cooler Cleaning Procedure Model: ALL Engine Family: ALL DESCRIPTION Some Charge Air Coolers (CACs) may experience internal contamination and will require cleaning. The following procedure demonstrates cleaning CACs on a bench 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) | 12-353-01 | | Charge Air Cooler (CAC) Adapter Flushing Kit | 09-925-01 | | Charge Air Cooler (CAC) Pressure Test Kit | ZTSE4341 | Table 2 . Parts Information. | Part Number | Description | Quantity | | --- | --- | --- | | 2512460C1 | Fluid, EGR Cleaning | 5 gal | SERVICE PROCEDURE PREPARATION GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human health and the environment. Handle all fluids and other contaminated materials (such as filters or rags) in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other contaminated materials according to applicable regulations. © 2013 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners. 1 SERVICE PROCEDURE PREPARATION (CONT.) WARNING: Park vehicle on hard flat surface, turn the engine off, set the parking brake, and block the wheels to prevent the vehicle from moving in both directions. Failure to do so may result in property damage, personal injury, and / or death. WARNING: If the vehicle must be raised, do not work under the vehicle supported only by jacks. Jacks can slip or fall over, potentially resulting in property damage, personal injury, and / or death. WARNING: Always wear safe eye protection when performing vehicle maintenance. Failure to do so may result in personal injury and / or death. WARNING: Keep flames or sparks away from vehicle and do not smoke while servicing the vehicle’s batteries. Batteries expel explosive gases. Failure to do so may result in property damage, personal injury, and / or death. WARNING: Remove the ground cable from the negative terminal of the battery box before disconnecting any electrical components. Always connect the ground cable last. Failure to do so may result in property damage, personal injury, and / or death. NOTE: This procedure applies to High Pressure (HP) Charge Air Coolers (CAC) only. Low Pressure (LP) CACs will be addressed at a later date. 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. 4. Remove CAC from vehicle. Refer to the following: • S12059 Service Manual Radiator / Cooling System-FE Bus-3100 Bus • S12049 Service Manual Section Radiator / Cooling System Service Manual-Model: LoneStar®with EPA 10 1998 Federal Emissions Only • S12043 Service Manual Section Radiator / Cooling System Service Manual-Model: RE Bus with Side-Mounted Cooling Package SERVICE PROCEDURE PREPARATION (CONT.) • S12041 Service Manual Section Radiator / Cooling System Service Manual-Model: LoneStar® with EPA 10 Emissions • S12039 Service Manual Radiator / Cooling System-AC Bus • S12037 Service Manual Radiator / Cooling System Service Manual-TerraStar® • S12036 Service Manual Section Radiator / Cooling System Service Manual-Model: WorkStar® and Model: TranStar® • S12034 Service Manual Section Radiator / Cooling System Service Manual-Model: 9800 • S12029 Service Manual Section Radiator / Cooling System Service Manual-Model: DuraStar® with EPA 2010 Federal Emissions Only • S12023 Service Manual Side Mount Cooling Package-RE Bus • S12022 Service Manual Radiator / Cooling System-WorkStar® • S12021 Service Manual Radiator / Cooling System-ProStar® • S12019 Service Manual Section Ra

FAQs

What problem does this procedure address for charge air coolers (CACs)?

Some charge air coolers may develop internal contamination and require cleaning using the provided bench procedure and test/flush kits.

Which fluids and contaminated materials handling requirements are included?

Engine fluids (oil, fuel, coolant) and other contaminated materials must be handled according to applicable regulations, with recycling or disposal performed as required.

How should the CAC be pressure tested according to the procedure?

The CAC is pressure tested on a bench only when internally contaminated. Do not check for leakage by submerging the CAC in a radiator test tank; most CACs will show leakage when submerged.

Sep 27, 2026

Upload by Aldword