Charge Air Cooler Diagnosis (Charge Air Cooler Air Leak Test)
Charge Air Cooler Diagnosis (Charge Air Cooler Air Leak Test)
Diagnostic Instructions
* Perform theDiagnostic System Check - Vehicle (Initial Inspection and Diagnostic Overview) prior to using this diagnostic procedure.
* ReviewStrategy Based Diagnosis (Initial Inspection and Diagnostic Overview) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (Initial Inspection and Diagnostic Overview) provides an overview of each diagnostic category.
Reference Information
Special Tools
* EN 47603 - Compression Gage Adapter
* J 46091 - Charge Air Cooler Tester
* J 46091-5 - Charge Air Cooler Tester Adapter
J 46091-1 Pressure Regulator Adjustment
Note
Some J 46091-1 regulators may have the adjusting knob riveted in place. The rivet head must be drilled out with a 5/16 inch drill bit before adjustment. Do not drill more than 1/8 inch in depth, or just enough to remove the rivet head. The rivet shaft does not have to be removed from the regulator.
1. Connect the EN 47603 - Gage Adapter compression adapter to the J 46091 - Tester gage set and connect shop air to the J 46091 - Tester .
2. Open the shutoff valve, then slowly turn the regulator on the J 46091 - Tester clockwise until the gage reads 206 kPa (30 psi).
3. Close the air supply valve and remove the EN 47603 - Gage Adapter from the gage assembly.
4. The gage set is now calibrated to perform the test.
Charge Air Cooler Outlet Connection (Engine Air Intake COLD Side)
Note
It is not necessary to remove the charge air cooler from the vehicle to perform this test.
1. Refer to Intake Air Heater Replacement (Service and Repair) for intake air heater removal.
2. Install the J 46091-5 - Charge Air Cooler Tester Adapter plate and gaskets on the inlet tube studs.
Caution: Refer to Fastener Caution (Fastener Caution) .
3. Install the 2 intake air heater nuts and tighten the nuts to 8 Nm (70 lb in) .
Charge Air Cooler Inlet Connection (Engine Air Intake HOT Side)
Note
After removing the intake manifold cover, protect the engine opening in order to prevent entry of objects.
1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (Service and Repair) .
2. Loosen the clamp (1) that fastens the left air cooler duct (4) to the turbocharger.
Note
* After removing the charged air cooler duct, cover the turbocharger opening 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.
3. Remove the left charge air cooler inlet duct connector (4) from the turbocharger.
Caution: Refer to Fastener Caution (Fastener Caution) .
4. Use the clamp to attach the J 45091-2 from the J 46091 - Tester to the duct connector and tighten the clamp to 8 Nm (70 lb in) .
5. Secure the J 45091-2 (1) safety cable (2) to a safe location (3).
Warning: Refer to Charge Air Cooler Warning (Service Precautions) .
6. Attach the gage/regulator assembly from the J 46091 - Tester to the quick disconnect fitting on the J 45091-2 .
7. Remove both fender wheelhouse liners. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (Service and Repair) andFront Wheelhouse Liner Replacement - Left Side (Chevrolet) (Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (Service and Repair) .
8. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
9. Remove the air cleaner box tray bracket.
Leak Test - Air Pressure Application
Warning: Refer to Charge Air Cooler Warning (Service Precautions) .
Note
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.
4. Perform a DPF Service Regeneration with a scan tool. Refer to Diesel Particulate Filter (DPF) Service Regeneration (Diesel Particulate Filter (DPF) Service Regeneration)
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.
Caution: Refer to Fastener Caution (Fastener Caution) .
3. Connect the charge air hose to the turbocharger and tighten the clamp to 8 Nm (70 lb in) .
4. Remove the adapter plate and install the intake air heater. Refer to Intake Air Heater Replacement (Service and Repair) .
5. Install both fender wheelhouse liners. Refer to Front Wheelhouse Liner Replacement - Right Side (Chevrolet) (Service and Repair)Front Wheelhouse Liner Replacement - Right Side (GMC) (Service and Repair) andFront Wheelhouse Liner Replacement - Left Side (Chevrolet) (Service and Repair)Front Wheelhouse Liner Replacement - Left Side (GMC) (Service and Repair) .
6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
7. Install the air cleaner boxy tray bracket.