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Home >> Chevy Truck >> 2008 >> Express 3500 V8-6.6L DSL Turbo >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Testing and Inspection >> Component Tests and General Diagnostics >> Charge Air Cooler Diagnosis (Charge Air Cooler Air Leak Test)

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 prior to using this diagnostic procedure. Initial Inspection and Diagnostic Overview
* Strategy Based Diagnosis
* Diagnostic Procedure Instructions

Special Tools
* J 46091 Charge Air Cooler Tester
* J-46091-10 Charge Air Cooler Tester Adapter

Charge Air Cooler Outlet Connection (Engine Air Intake COLD Side)

Important: It is not necessary to remove the charge air cooler from the vehicle to perform this test.




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

Important: 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-46091-10 adapter to the charge air duct.
4. Use the clamp to secure the adapter to the charge air duct.

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

Caution: To prevent possible injury from the coupler blowing off the charge air cooler hose during the test, connect the safety cable before applying air pressure.




5. Secure the safety cable.

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





1. Remove the engine cover.
2. Remove the air cleaner assembly.
3. Loosen the clamp (1) that fastens the left air cooler duct (4) to turbocharger.

Important:
* After removing the charged 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.

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

4. Use the clamp to attach the gage couple from the J 46091 adapter to the charge air hose.

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

5. Secure the safety cable.

Caution: Refer to Charge Air Cooler Caution.

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

Leak Test - Air Pressure Application

Caution: Refer to Charge Air Cooler Caution.

Important: 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 gage/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 gage reads 205 kPa (30 psi).
3. Close the air valve and monitor the gage for 15 seconds. 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 seconds, 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 CAC system. If no other leaks are found, assemble the vehicle and clear the DTC information with a scan tool.

Notice: After performing the system repair, perform the following:

* A code clear with a scan tool, regardless of whether or not a DTC is set

* A Diesel Particulate Filter (DPF) Service Regeneration with a scan tool

Perform the above in order to remove soot from the DPF and avoid possible DPF failure.

Perform a Service Regeneration with a scan tool. Refer to Exhaust Particulate Filter Cleaning (LMM DPF Service Regeneration) Exhaust Particulate Filter Cleaning (LMM DPF Regeneration Enable).

Leak Test Passes

If the pressure drop is less than 34 kPa (5 psi) in 15 seconds, the leak test passes. Remove the tester 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.

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

4. Install the engine cover.
5. Install the air cleaner assembly.
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