To check the charge air cooler for cracked tubes or header, remove the inlet and outlet hoses from the cooler.
The charge air cooler does not have to be removed from the chassis.
Use protective caps from the Air Handling Clean Care Kit, Part Number 4919498, to cover the open points on the
engine plumbing and charger-air cooler.
To perform the leak test, use tool, Part Number 3824556.
Install the cap over the outlet side of the cooler. Install the gauge end of the tool with a regulated shop air supply line
and a shutoff valve to the inlet side of the cooler.
Apply air pressure to the cooler until the pressure gauge reads a steady 207 kPa [30 psi) of air pressure.
Shut off the airflow to the cooler and start a stopwatch at the same time. Record the leakage at 15 seconds.
If the pressure drop is 48 kPa [7 psi] or less in 15 seconds, the cooler is operational.
If the pressure drop is greater than 48 kPa [7 psi) in 15 seconds, check all connections again.
Determine if the pressure drop is caused by a leak in the charge air cooler or from a leaky connection. Use a spray
bottle filled with soapy water, applied to all hose connections. Watch for bubbles to appear at the location of the leak.
If the pressure drop is caused by a leaky connection, repair the connection and repeat the test. If the leak is within the charge air cooler, repeat the test to verify the accuracy of the pressure drop measurement. Similar pressure drop readings must be obtained in at least three consecutive tests before the reading can be considered accurate.
NOTE: If a charge-air cooler leak causes a pressure drop of more than 48 kPa [7 psi] in 15 seconds, it will appear
as a major leak in a leak tank.
If the pressure drop is greater than 48 kPa [7 psi) in 15 seconds, the charge air cooler must be replaced.
Refer to the OEM service manual for replacement instructions.
NOTE: Charge-air coolers are not designed to be 100- percent leak free. If the pressure drop is less than 48 kPa
[7 psi] in 15 seconds, the charge air cooler does not need to be replaced.
