Intercooler: Testing and Inspection

Charge Air Cooler (CAC) Leak Test

1. NOTE: Any residual coolant in the Charge Air Cooler (CAC) could block air from escaping through a small leak and result in an inaccurate test result. Therefore, all residual coolant must be removed from the CAC prior to testing.

With the Charge Air Cooler (CAC) coolant inlet pointing downward, rock the CAC in a circular motion to remove all residual coolant.





2. Leak test the CAC as follows:

1. Plug or cap the coolant outlet.

2. Apply 276 kPa (40 psi) of compressed air to the coolant inlet.

3. Completely submerge the CAC in water and observe the air inlet and outlet for a small stream of air bubbles (may take up to 5 minutes). If any stream of air bubbles is observed, the CAC has an internal leak and a new CAC must be installed.