Exhaust System Leak Test

Exhaust System Leak Test

Test Step 1 - Exhaust System for Leak Check

• Turn the ignition off.

• Raise the vehicle.


The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time.

• Connect exhaust cone #8404-EC or #8404-EC to air pressure regulator (with hose) #W-18-MIL-1146AS.


The air pressure must not exceed 4 psi, otherwise engine damage can occur.

• Attach shop air to the air pressure regulator.

• Adjust the air pressure regulator to 4 psi.

• Insert the exhaust cone into the vehicle tail pipe.

• If the vehicle is equipped with dual exhaust. Use the #8404-ECT with equipped attached plug , plug one side of the dual exhaust pipe. Pressurize the other as described above.

Apply an equivalent air leak detector to the following areas:

• All welded joints from 6 inches rearward of the downstream O2 sensor forward.

• O2 sensor seal points.

• O2 sensor boss welds.

• Flange/joint connections.

• Exhaust manifold to cylinder head connections.

• EGR solenoid gasket base and tube seal points (if equipped).

• Watch for the leak detector solution water to bubble.

• Use the following definitions to help determine if system or component repair/replacement is necessary.

• A Type 1 Leak is defined as a leak where very small foam-like bubbles (1mm or less) appear.

• Any Type 1 or greater leaks found in welded joints, O2 sensor seal points or O2 sensor boss welds must be repaired or the component must be replaced.

• A Type 2 Leak is defined as a leak where larger bubbles (8mm or greater) appear.

• Any Type 2 or greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections, or EGR gasket and tube seal points must be repaired or the components must be replaced.






• If a leak is found that matches the above definition, repair or replace the component as necessary.

• Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.

Were any exhaust leaks found?

Yes

• Repair or replace the leaking exhaust parts as necessary.

• Perform the PCM Verification Test. Refer to => [ PCM Verification Test ] PCM Verification Test.

No

• Test complete.