The charge air cooler (CAC) plays a critical role in diesel engine performance, and its failure can have devastating consequences for heavy-duty vehicles. This essential component cools compressed air before it enters the engine, improving combustion efficiency and preventing overheating.

Several key factors contribute to charge air cooler failure:

• Metal fatigue is the primary culprit. Repeated thermal stress of expansion and contraction cause the tube-to-header joints to crack and leak.
• Corrosion from moisture accumulation and environmental exposure cause the material to degrade and weaken over time.
• Physical damage from road debris, vibration, or improper maintenance can also lead to significant problems.

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