Charge Air Cooler (Aftercooler) Maintenance Guide

What Is a Charge Air Cooler?

A charge air cooler (CAC), also called an aftercooler or intercooler, cools the compressed air from the turbocharger before it enters the engine.

Inspection Schedule

• Every 50,000 miles: Visual inspection for leaks, damage, and fin condition
• Every 100,000 miles: Pressure test at 30 PSI
• Every 200,000 miles: Consider proactive replacement

Common Failure Modes

Internal Leaks — Cracks in the core allow boost pressure to escape.

External Contamination — Road debris and insects block fins.

Corrosion — Salt and road chemicals corrode aluminum cores.

Cleaning Procedure

1. Remove CAC from vehicle

2. Flush internally with clean water

3. Clean fins with low-pressure compressed air

4. Inspect for cracks with pressure test

5. Replace if any leaks detected