Intercooler: Testing and Inspection

DIAGNOSIS AND TESTING

CHARGE AIR COOLER SYSTEM - LEAKS
Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or plumbing. Fuel staining on the exhaust manifold can also be an indication that there are leaks in the air system. The following procedure outlines how to check for leaks in the charge air cooler system.

This procedure can also be used to check for leaks in the wastegate signal line or the wastegate canister.





1. Loosen clamp and remove air inlet hose from turbocharger.
2. Insert Special Tool 9022 Adapter into the turbocharger inlet. Tighten tool clamp to 8 Nm (72 inch lbs.).

CAUTION: Do not apply more than 138 kPa (20 psi) air pressure to the charge air cooler system, severe damage to the charge air cooler system may occur.

3. Connect a regulated air supply to air fitting on Tool 9022 Adapter. Set air pressure to a Maximum of 138 kPa (20 psi).
4. Using soapy water check the rubber sleeves, charge air cooler and intake manifold for leaks.
5. Using soapy water check for leaks at the wastegate signal line, wastegate canister and wastegate command valve.