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Charge Air Cooler Diagnosis (Charge Air Cooler Air Leak Test)




Charge Air Cooler Diagnosis (Charge Air Cooler 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

For equivalent regional tools, refer to Special Tools (Tools and Equipment)

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 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. Loosen the charge air cooler clamp (1) that fastens the right air cooler duct to the intake air valve (2).

Note: After removing the charge air cooler duct, protect the intake air valve opening in order to prevent entry of objects.

2. Remove the right charge air cooler duct (3) from the intake air valve inlet.




3. Install the J 46091 - Bleed-Off Coupler (1) to the charge air duct.
4. Use the clamp to secure the coupler to the charge air duct and tighten the clamp to 8 Nm (70 lb in).
Warning: Refer to Charge Air Cooler Warning (Service Precautions).

5. Secure the coupler safety cable (2) to a safe location (3).

Charge Air Cooler Inlet Connection (Engine Air Intake HOT Side)





1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
2. Loosen the clamp (1) that fastens the charge air cooler inlet duct (4) to the turbocharger.

Note:
* After removing the charge air cooler duct, cover the turbocharger in order 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.

3. Remove the charge air cooler inlet duct (4) from the turbocharger.
4. Use the clamp to attach the gauge coupler from the J 46091 - Tester to the charge air hose and torque the clamp to 8 Nm (70 lb in).
5. Secure the safety cable.
Warning: Refer to Charge Air Cooler Warning (Service Precautions).

6. Attach the gauge/regulator assembly from the J 46091 - Tester to the quick disconnect fitting on the gauge coupler.

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 gauge/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 gauge reads 205 kPa (30 psi).
3. Close the air valve and monitor the gauge for 15 s. Note any decrease in air pressure.
4. Repeat the test 3 times to verify the results.

Leak Test Fails

If the pressure drop is greater than 34 kPa (5 psi) in 15 s, 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 charge air cooler system. If no other leaks are found, assemble the vehicle and clear the DTC information with a scan tool.
4. Perform a 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 s, the leak test passes. Remove the tester by performing the following procedure:

1. Slowly bleed the air from the cooler by depressing or opening the relief valve on the bleed-off coupler.
2. Remove the air hose, gauge/regulator assembly, and both couplers.
3. Connect the charge air hose to the turbocharger and tighten the clamp to 8 Nm (70 lb in).
4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).

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