Cooling System Leak Testing (Charge Air Cooling)

Cooling System Leak Testing (Charge Air Cooling)

Tools Required

* J 24460-01 Cooling System Pressure Tester
* GE-47844 Charge Air Cooling System Pressure Test Adapter

Caution: To avoid being burned, do not remove the charge air coolant cap while the system is hot. The cooling system will release scalding fluid and steam under pressure if charge air coolant cap is removed while the system is still hot.

Important: Ensure the intercooler system is cool and that the pump is not ON.

1. Remove the manifold sight shield.





Important: It is normal to have a very small pocket of air at the top of the system below the fill cap on a properly filled charge air cooling system.

2. Remove the charge air coolant cap.

Notice: Refer to Fastener Notice.

3. Install the GE-47844 onto the charge air cooler cap port.

Tighten the bolts to 10 N.m (89 lb in).

4. Use the J 24460-01 with GE-47844 in order to apply pressure to the cooling system. Do not exceed 34 kPa (5 psi).
5. The cooling system should hold 34 kPa (5 psi) at least 2 minutes. Observe the gage for any pressure loss.
6. Repair any leaks as required.
7. Remove the GE-47844 from the charge air cooler cap port.




8. Install the charge air cooler cooling fill cap.
9. Ensure the charge air cooler cooling fill cap is installed in the proper orientation:
^ The alignment boss (1) is at the rear of the charge air cooler manifold.
^ The alignment boss (2) is at the front of the charge air cooler cooling filling cap.




10. Install the charge air coolant cap bolts.

Tighten the bolts to 10 N.m (89 lb in).

11. Install the manifold sight shield.