VIN L
Charge Air Cooler Diagnosis (Full System Air Leak Test)
Diagnostic Instructions
* Perform the Diagnostic System Check - Vehicle (Diagnostic System Check - Vehicle) prior to using this diagnostic procedure.
* Review Strategy Based Diagnosis (Strategy Based Diagnosis) for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions (Diagnostic Procedure Instructions) provides an overview of each diagnostic category.
Reference Information
Special Tools
* EN 47603 - Compression Gauge Adapter
* J 46091 - Charge Air Cooler Tester
* J 46091-15 - Engine Pressure Test 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 - Gauge Adapter compression adapter to the J 46091 - Tester gauge 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 gauge reads 206 kPa (30 psi).
3. Close the air supply valve and remove the EN 47603 - Gauge Adapter from the gauge assembly.
4. The gauge set is now calibrated to perform the test.
Charge Air Cooler Inlet Connection (Engine Air Intake Hot Side)
Warning: Refer to Charge Air Cooler Warning (Service Precautions).
Note: After removing the intake manifold cover, protect the engine opening to prevent entry of objects.
1. Loosen the clamp (1) that fastens the left air cooler duct to the turbocharger.
Note:
* After removing the charge air cooler duct, protect the turbocharger opening to prevent entry of objects.
* Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
2. Remove the left charge air cooler inlet duct connector from the turbocharger.
3. Remove the engine cover. Refer to Engine Cover Replacement (Service and Repair).
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
Caution: Refer to Fastener Caution (Fastener Caution).
5. Use the clamp to attach the J-46091-2 (1) from the J 46091 - Tester to the duct connector, and tighten the clamp to 8 Nm (70 lb in).
6. Secure the J 46091 - Tester (1) safety cable (2) to a safe location (3).
Turbocharger Exhaust Pipe Connection
Warning: Refer to Charge Air Cooler Warning (Service Precautions).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Remove the catalytic converter. Refer to Catalytic Converter Replacement (V6) (Catalytic Converter Replacement) Catalytic Converter Replacement (V8) (Catalytic Converter Replacement) Catalytic Converter Replacement (LMM) (Catalytic Converter Replacement) Catalytic Converter Replacement (LGH) (Catalytic Converter Replacement).
Note:
* An improperly seated J 46091-15 - Test Adapter will cause an excessive air leak and hissing noise.
* An early version of the J 46091-15 - Test Adapter has a quick-connect air fitting installed in the center of the adaptor. Remove the quick-connect air fitting and install a 1/8 pipe plug.
3. Install the J 46091-15 - Test Adapter with the exhaust pipe clamp to the turbocharger exhaust pipe using the clamp from the catalytic converter.
Air Pressure Application
Warning: Refer to Charge Air Cooler Warning (Service Precautions).
1. Attach the gauge/regulator assembly from the J 46091 - Tester to the quick disconnect fitting on the J-46091-2.
2. Connect the air supply to the air valve on the gauge/regulator assembly.
3. Open the air supply valve slowly, increasing the air pressure to a maximum of 206 kPa (30 psi) while listening for abnormal air leaks.
Note:
* An air leak hissing sound at the EGR valve vent port is normal.
* For accurate readings you must allow approximately 30 seconds for the air pressure to stabilize.
* The engine will not hold pressure if the gauge valve is turned OFF.
* If an excessive air leak hissing sound at turbocharger outlet is present, rotate the crankshaft 90 degrees.
4. Leave the valve ON for the duration of the test.
Leak Test Results
Note:
* An air leak that appears as small bubbles or foaming is normal.
* Intake Air Heater gaskets that show a small leak or foaming is normal.
1. With the air valve ON, the gauge on the regulator assembly should read greater than 158 kPa (23 psi), and there should be no abnormal air leaks.
• If the air pressure gauge reads less than 158 kPa (23 psi) with constant air pressure applied, and audible air leaks are present, the leak test has failed. Perform the following procedure:
1. Inspect for air leaks by listening for excessive hissing sounds.
2. Inspect for air leaks by using a pump spray bottle to apply a soapy solution, while observing for excessive soapy bubbles at all of the following engine locations:
* Charge air cooler pipes/hoses connections
* Charge air cooler core
* EGR valve gaskets
* EGR valve cooler gaskets
* Exhaust manifold gaskets
* Turbocharger gaskets, inlet and outlet connections
* Intake manifold gaskets
• If any abnormal leaks are found, replace the affected gasket or component as necessary.
2. Retest the engine system for air leaks. The gauge on the regulator assembly should read greater than 158 kPa (23 psi), and there should be no abnormal air leaks.
• If the gauge reads less than 158 kPa (23 psi) with air valve ON, and audible air leaks are present, recheck for air leaks.
3. If no other air leaks are found, assemble the vehicle. Remove the tester and adapters by performing the following procedure:
1. Slowly bleed the air from the cooler by depressing the relief valve on the adapter.
2. Remove the air hose, gauge/regulator assembly, and both adapters.
3. Connect the charge air hose to the turbocharger with the clamp and tighten the clamp to 8 Nm (70 lb in).
4. Install the catalytic converter. Refer to Catalytic Converter Replacement (V6) (Catalytic Converter Replacement) Catalytic Converter Replacement (V8) (Catalytic Converter Replacement) Catalytic Converter Replacement (LMM) (Catalytic Converter Replacement) Catalytic Converter Replacement (LGH) (Catalytic Converter Replacement).
5. Clear all DTC information with a scan tool.