Intercooler: Testing and Inspection
CHARGE AIR COOLER DIAGNOSIS
DIAGNOSTIC INSTRUCTIONS
- Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Initial Inspection and Diagnostic Overview
- Review Strategy Based Diagnosis for an overview of the diagnostic approach.
- Diagnostic Procedure Instructions provides an overview of each diagnostic category.
CHARGE AIR COOLER OUTLET CONNECTION (ENGINE AIR INTAKE COLD SIDE)
IMPORTANT: It is not necessary to remove the charge air cooler from the vehicle to perform this test.
1. Refer to Intake Air Heater Replacement for intake air heater removal.
2. Install the J-46091-5 plate and gaskets on the inlet tube studs.
3. NOTE: Refer to Fastener Notice.
Install the 2 intake air heater nuts.
Tighten the nuts to 8 N.m (70 lb in).
CHARGE AIR COOLER INLET CONNECTION (ENGINE AIR INTAKE HOT SIDE)
1. IMPORTANT: After removing the intake manifold cover, protect the engine opening with tape in order to prevent entry of objects.
Remove the intake manifold cover.
2. Loosen the right clamp that fastens the left air cooler duct to turbocharger (1).
3. IMPORTANT:
- After removing the charged air cooler duct, cover the turbocharger opening with tape in order to prevent entry of objects.
- Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
Remove the left charge air cooler inlet duct connector (4) from the turbocharger.
4. NOTE: Refer to Fastener Notice.
Use the clamp to attach the gage couple from the J 46091 to the charge air hose.
Tighten the clamp to 8 N.m (70 lb in).
5. Secure the safety cable.
6. CAUTION: Refer to Charge Air Cooler Caution.
Attach the gage/regulator assembly from the J 46091 to the quick disconnect fitting on the gage coupler.
LEAK TEST - AIR PRESSURE APPLICATION
CAUTION: Refer to Charge Air Cooler Caution.
IMPORTANT: Charge air coolers are not required to be leak proof. DO NOT test the cooler for leakage by submerging it in a radiator test tank. Almost all charge air cooler units will show leakage if they are submerged.
1. Connect the filtered air supply to the air valve on the gage/regulator assembly.
2. Open the air valve SLOWLY, increasing the air pressure in 34-69 kPa (5-10 psi) increments while listening for air leaks. Continue increasing the air pressure until the gage reads 205 kPa (30 psi).
3. Close the air valve and monitor the gage for 15 seconds. Note any decrease in air pressure.
4. Repeat the test 3 times to verify the results.
Leak Test Fails
If the pressure drop is more than 34 kPa (5 psi) in 15 seconds, the leak test has failed. Perform the following procedure:
1. Inspect for air leaks using a pump spray bottle to apply a soapy solution to the pipes/hoses, charge air cooler hose connections, and charge air cooler core. Observe for bubbles.
2. Replace or tighten the affected component as necessary.
3. Retest the CAC system. If no other leaks are found, assemble the vehicle and clear the DTC information with a scan tool.
Leak Test Passes
If the pressure drop is less than 34 kPa (5 psi) in 15 seconds, the leak test passes. Remove the tester by performing the following procedure:
1. Slowly bleed the air from the cooler by depressing the relief valve on the adapter plate.
2. Remove the air hose, gage/regulator assembly, and both adapters.
3. NOTE: Refer to Fastener Notice.
Connect the charge air hose to the turbocharger.
Tighten the clamp to 8 N.m (70 lb in).
4. Remove the adapter plate and install the intake air heater.