Charge Air Cooler (CAC) Cleaning. General Procedures

Activation

1. 1
   Position the CAC horizontally with the inlet and outlet ports facing up.
2. 2
3. 3
   Add an appropriate amount of a commercially available cleaning agent, such as Simple Green Pro HD or an equivalent CAC cleaner. Follow the manufacturer's cleaning instructions. Fill the CAC to 40% of its volume with water.
4. 4
   Lift one end of the CAC and shake it by hand for at least 5 minutes.
5. 5
   Lift the opposite end of the CAC and shake it by hand for at least 5 minutes.
6. 6
   Drain the CAC.
7. 7
   Thoroughly rinse the CAC with clean water.
8. 8
   Repeat steps 1 through 6 until no contamination is found in the rinse water.
9. 9
   Allow the CAC to air dry.
10. 10
    Install a commercially available CAC tester on the CAC, following the tester manufacturer's installation instructions.
11. 11
    Tighten the clamps to 5 N·m.
12. 12
    Slowly apply air pressure up to 150 kPa (22 psi).
13. 13
    Allow the CAC to stand for several minutes and check for any loss of pressure.
14. 14
    Release the air pressure.
15. 15
    Repeat steps 12 through 14 as many times as necessary to verify the readings. A reading is considered verified when 3 consecutive tests show approximately the same pressure drop.
16. 16
    If the pressure loss exceeds 10 kPa (1.5 psi) per minute, install a new CAC.
    Refer to: Charge Air Cooler (CAC) (303-12B Intake Air Distribution and Filtering — 1.6 L EcoBoost (132 kW/180 L hp) — Sigma, Removal and Installation).