Charge Air Cooler Diagnosis (Full System Air Leak Test)

Charge Air Cooler Diagnosis (Full System Air Leak Test)

Diagnostic Instructions

* Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
* Review Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions provides an overview of each diagnostic category.

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






Caution: Refer to Charge Air Cooler Caution.

Important: 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 (4) to the turbocharger.

Important:
* 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.

Remove the left charge air cooler inlet duct connector (4) from the turbocharger.






Notice: Refer to Fastener Notice.

2. Use the clamp to attach the J-46091-3 (1) from the J 46091 to the duct connector (4).

Tighten the clamp to 8 N.m (70 lb in).

3. Secure the J 46091 (1) safety cable (2) to a safe location (3).

Turbocharger Exhaust Pipe Connection

Caution: Refer to Charge Air Cooler Caution.

1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Remove the catalytic converter.
3. Install the J-46091-15 Adapter with the exhaust pipe clamp to the turbocharger exhaust pipe using the clamp from the catalytic converter.

Air Pressure Application

Caution: Refer to Charge Air Cooler Caution.

1. Attach the gage/regulator assembly from the J 46091 to the quick disconnect fitting on the J-46091-15.
2. Connect the air supply to the air valve on the gage/regulator assembly.
3. Open the air supply valve slowly, increasing the air pressure in 34-69 kPa (5-10 psi) increments while listening for air leaks.

Important:
* 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.

Continue increasing the air pressure until the air valve is fully open.

Leak Test Fails

Important: An air leak hissing sound at the EGR valve vent port is normal.

If the pressure gage reads less than 158 kPa (23 psi) with constant air pressure, 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

3. Replace the affected gasket or component, as necessary.
4. Retest the engine system. If no other leaks are found, assemble the vehicle and clear the DTC information with a scan tool.

Leak Test Passes

If the pressure gage reads greater than 158 kPa (23 psi) with a constant air pressure, and audible air leaks are not present, the leak test passes. 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 plate.
2. Remove the air hose, gage/regulator assembly, and both adapters.
3. Connect the charge air hose to the turbocharger.
4. Install the catalytic converter.

Tighten the clamp to 8 N.m (70 lb in).