How to Check Charge Air Cooler For Leaks

10 mins read

Last Updated on September 16, 2022

To test charge air cooler for leaks, you need to apply pressure to check its seal. You can use a pressure tester like the Dura-Lite Tester-Kit, which can help you identify any leaks in the system. The kit is fast and easy to use, and comes with the exact part you need. In addition to charge air coolers, Dura-Lite also offers a variety of radiator and charge air cooler solutions.

Test kit

One of the best ways to test for leaks in your charge air cooler is to use a test kit. A good test kit will include everything you need to properly check your intercooler, including gauges and a pressure regulator. These kits are made from high-quality materials and have coatings that help prolong the life of the tester. The Dura-Lite Charge Air Cooler Tester-Kit is a great option if you’re not sure how to test your car’s intercooler yourself.

The test kit is easy to use and can even be performed without removing your Charge Air Cooler from the vehicle. You’ll save a lot of money by repairing a leak before it gets out of hand. In addition to saving fuel, the leak detection kit can help you limit downtime, save money and limit fuel expenses. The Quick Check Leak Test Kit can be purchased from your local dealer and can be used to check your vehicle’s charge air cooler for leaks.

how to check charge air cooler for leaks

Pressure regulator

Many drivers don’t consider the charge air cooler (CAC) as a crucial part of their diesel engine. But a leaking CAC is a serious problem, one that can affect your fuel economy and overall productivity. In some cases, the leaks may go unnoticed, and you may be tempted to blame the lead foot or bad driving habits for the dreaded problem. However, if you’re concerned about these problems, you can try this simple test to detect leaks in the system before they cause you any trouble.

A simple test to check the pressure regulator on a charge air cooler is to pressurize it. You should take a pressure gauge and connect it to the air-cooled part of the vehicle. If the pressure drops more than 34 kPa within 15 seconds, you should replace the charge air cooler. A good pressure gauge is available from your OEM service manual. If you don’t have one, you can buy a test kit to help you find the leak.

Before you begin checking the pressure regulator, it’s important to make sure that your car is running smoothly. The charge air cooler can fail just like any other component in your engine, but it’s particularly difficult to detect a leak before it’s too late. A significant leak can lower your vehicle’s horsepower and fuel efficiency by as much as 50%. If you suspect a leak, be sure to get the vehicle to a professional mechanic for proper diagnosis and repair.

If your car has a manual pressure gauge, you can install one on the intake manifold. Plug in the gauge on the hot side of the charge air cooler and set it to 60 PSI. If the difference is greater than this, your charge air cooler is plugging. Clean it or replace it. To prevent erratic test results, lock the fan drive in ON mode. Then attach the tester to the cooler hose.

Inspection procedure

A cooling system inspection checklist can help you find problems in a cooling system. These checks are based on the Uniform Inspection Guidelines of the Motorist Assurance Program. They also serve as guidelines for companies that provide cooling system services. They are vitally important. You must be thorough when performing these checks, as any inaccuracy in your report could cast doubt on your professionalism. Here are some important tips to perform a thorough inspection:

Firstly, disconnect the hoses from the charge air cooler. If you detect any of them leaking, check the connections and replace them if necessary. Next, inspect the charge air cooler for leaks by running a pressure test with a solution of hot water and detergent. If there are bubbles or other signs of leakage, replace the charge air cooler. Repeat the test with a different hose to confirm that there is no leak within the charge air cooler.

Next, check for internal contamination. Some trucks have a manual switch to lock the fan while others operate at rated RPM or under load. If you notice a difference of more than 21 kPa, the charge air cooler has plugged up and needs to be cleaned or replaced. To avoid an erratic result, you can lock the fan drive in ON mode by attaching a jumper to the temperature switch. You can also supply shop air to lock the fan drive.

Common causes of leaks

Many leaks in a car’s charge air cooler are not noticed at all. They may be a result of thermal fatigue, but they can also cause improper combustion and impaired fuel economy. In some cases, leaks can occur in the air ducts or high pressure hoses. In other cases, the problem could be as simple as a cracked hose or disconnected air duct. Other causes of leaks in a car’s charge air cooler include faulty sensors, poor airflow, or deterioration of the fan clutch.

The most common cause of charge air cooler failure is faulty mounting. If the mounting bushings are not changed regularly, they may wear out. When the unit moves, the metal can flex and crack under pressure. If the leaks are extreme, the car can experience exhaust overheating and even fire. Therefore, you should have a qualified technician inspect your car’s charge air cooler regularly. If you suspect that your car’s charge air cooler is leaking, be sure to replace it as soon as possible.

Besides causing a car to overheat, leaks in the charge air cooler can also result in reduced boost pressure. Visual cracks along the tanks and loss of boost pressure are symptoms of leaks in charge air coolers, but most leaks are too small to cause a noticeable loss in boost pressure. A cooling shop can check for leaks while it is still mounted in the truck. Using a leak detector is an effective way to detect this problem.

A leaking charge air cooler can affect all components of the vehicle’s engine. The resulting ash is a different type than that produced by the engine’s exhaust system. This ash clogs the diesel particulate filter prematurely. Other common symptoms of a leaking charge air cooler include excessive soot in the oil and premature turbo wear. The best way to determine whether a leak in the charge air cooler is causing these symptoms is to check the system with a leak detector kit.

Repair options

Fortunately, there are repair options for charge air cooler leaks. According to a 2011 study, 40 percent of trucks had a leaky CAC. This is an important issue because it could cause engine overheating or high fuel consumption. The best way to determine whether yours is leaking is to get a charge air cooler test kit, which includes a special gauge for pressure measurements. Apply pressure to the CAC for 15 seconds and check for any leakage by releasing the gauge. A pressure loss of five psi or more indicates a leaky CAC.

One of the most common causes of charge air cooler failure is the mounting. If you do not change the bushings regularly, you could cause the unit to shift. The unit’s vibration would cause the metal to flex and eventually crack under pressure. This could cause engine overheating and fires. In such a case, you should always have the unit inspected by a professional mechanic. If the leak is mild, you can attempt to plug the hole and run the vehicle as normal.

About The Author

Wendy Lee is a pop culture ninja who knows all the latest trends and gossip. She's also an animal lover, and will be friends with any creature that crosses her path. Wendy is an expert writer and can tackle any subject with ease. But most of all, she loves to travel - and she's not afraid to evangelize about it to anyone who'll listen! Wendy enjoys all kinds of Asian food and cultures, and she considers herself a bit of a ninja when it comes to eating spicy foods.