How do you test a charge air cooler?

How it Works

  1. Remove turbo hoses and clamps.
  2. Install Tester-Kit plugs and clamps. Mount gauge and double check system.
  3. Apply 30 psig of air. Remove air supply and check gauge. See chart (below) for Leak Down Rate Specifications.
  4. Release air. Test is now complete.

How do I know if my charge air cooler is leaking?

If you feel the constant heat and the coolant under the truck continuously filling coolant, it indicates a leak. A slight air leak can reduce the engine horsepower up to 50%. If you see rust present in the cooling radiator, it might damage or reduce the efficiency of the vehicle’s engine system.

What is the maximum test pressure for testing a charge air cooler for leaks?

30 PSI
NEVER TEST A CHARGED AIR COOLER USING MORE THAN 30 PSI OF AIR PRESSURE! NEVER POINT A LOADED CAC PLUG IN THE DIRECTION OF COWORKERS, THE PUBLIC, OR YOURSELF!

Can you repair a charge air cooler?

Aluminum Charge Air Cooler Repair Cracks in the weld that holds the tank to the core may be repairable. If tubes in the core are cracked or if tube-to-header joints leak, the cooler will then need to be recored or replaced.

What causes a charge air cooler to leak?

The most common causes of charge air cooler leaks are heat stress, constant engine vibration and vehicle accidents/collisions. Basically, the harsher the environment in which your truck or equipment runs, the more vulnerable it is to charge air cooler problems.

How do you check for boost leaks?

Smoke Testing for Boost Leaks: When chasing boost leaks, the humble and effective intake pressure test or smoke test is often used. Pressuring the intake, then spraying soapy water to look for bubbles, or using a workshop smoke tester will give a visual indication of boost leaks.

What is CAC in engine?

Your engine’s charge air cooler (CAC) is on the front line of defense against heat. It takes compressed air from the turbocharger, cooling it before sending it into your engine. The higher the compression of the air, the more dense the air becomes, resulting in increased engine efficiency.

Do intercoolers increase horsepower?

It also makes the compressed air denser as it enters the intake manifold, which causes a richer air-to-fuel mix in the engine’s cylinders. The result is increased power output. So, the answer to the question is yes! An intercooler does help to increase horsepower.

What is the difference between an intercooler and a charge air cooler?

The difference is that a “charge cooler” uses water to cool the air (it is a reverse radiator) and an intercooler uses air as the cooling medium. Since water has a greater heat carrying capacity than air a charge cooler is much smaller than an intercooler.