How To Maximize Fuel Mileage From Your Charge Air Cooler (CAC) - West End Rad
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How To Maximize Fuel Mileage From Your Charge Air Cooler (CAC)

With fuel prices hitting record high around the world, we know how important it is to maximize your fuel mileage. But if your charge air cooler (CAC) is leaking, you could be losing thousands of dollars annually. This post will break down how you can maximize your fuel mileage from your CAC and what to do if you suspect a leak.

What’s A Charge Air Cooler

A charge air cooler (CAC) is and important component of the turbo charger system on an internal combustion engine. The function of the CAC is to keep the intake air at the right temperature and density to improve fuel combustion, and to maximize power and fuel mileage.

Here at West End Radiators, we carry an extensive inventory of aftermarket CACs for all heavy-duty industries. We can manufacture a CAC to match your custom application as well as provide you a replace for a range of models.

Check out our online shop to see the replacement CACs we offer for a range of OEMs, including Freightliner, Kenworth and Peterbilt to name a few.

How To Know If Your Charge Air Cooler Is Leaking

There are several signs that a CAC may have developed significant leaks. Here’s a few things to look out for:

  • Loss of Engine Power
  • Increased Fuel Consumption
  • Increased exhaust smoke
  • High Soot Levels In Engine Oil
  • Premature Piston, Ring and Valve Failure
  • Turbo Charger and/or Exhaust Manifold Failure
  • Elevated Coolant Temperature

If a pressure drop test on a CAC at 30 psi shows a loss of 5 psi in 15 seconds, the CAC is defective and must be repaired or replaced.

How Much Money Will You In Fuel If Your Charge Air Cooler Is Leaking

Overall, a leaking CAC could cause a reduction in fuel economy by 6.15%.

Here’s an example to put things into perspective:

  •  Say your semi-truck uses 36.187 litres per 100 km fuel consumption
  • On average, you travel 965.6 km/day and spend $2.00L on diesel fuel cost
  • You would be spending $698.84 per day on fuel with a non leaking CAC

Now if your CAC is leaking…

  • We can add 6.15% to your daily fuel cost
  • This would increase your daily fuel cost by $42.97 
  • If on average, you work 25 days/month, you’re looking at spending an additional $1074.25/month on fuel

This means, with a leaking CAC you could spend an extra $12,891.00 per year on fuel! This is money that could easily be saved.

How To Maximize Fuel Mileage From Your Charge Air Cooler

The best way to maximize fuel mileage from your charge air cooler is to get it serviced regularly as well as to get the pressure checked.

West End Radiators is here to help! If you suspect that your CAC is leaking, please bring it to our shop for a complimentary pressure test. If we detect a serious leak, we will advise you on the most cost effective option to either repair or replace with new from our large inventory of parts. This service typically costs our customers between $75-$150 and can save you thousands in fuel.  Some exceptions may apply

Contact us for more details.

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