Charge Air Cooler Diagnosis (Induction System Smoke Test)

Charge Air Cooler Diagnosis (Induction System Smoke 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.

Circuit/System Description

The purpose of the Induction System Smoke Test is to aid in finding an air leak between the mass air flow sensor and turbocharger inlet. This test will also aid in finding air leaks in the crankcase ventilation system.

Reference Information

Special Tools

* GE 41413-SPT - High Intensity White Light

* GE 41413-200 - Evaporative Emission System Tester (EEST)
For equivalent regional tools, refer to Special Tools Tools and Equipment.

Smoke Test Application

1. Ignition OFF, remove the air filter restriction indicator and connect the GE 41413-200 to the vehicle at the air restriction indicator port.

2. Place the air filter in a disposable plastic bag and secure it in the air cleaner housing to help prevent smoke leakage.

3. Remove the engine cover. Refer to Engine Cover Replacement Service and Repair.

4. Apply smoke continuously with the GE 41413-200 while moving all duct work, pipes, and tubes.

Note: To improve the visibility of the smoke exiting the engine, illuminate the suspected leak area with the GE 41413-SPT and observe the area from different angles.

5. Verify smoke is not visible at the components listed below:

* Mass air flow sensor

* Air cleaner outlet duct

* Turbocharger air inlet adapter

* Crankcase depression regulator valve

* Upper intake manifold cover

* Positive crankcase Ventilation Hoses/Pipes/Tubes

* Positive Crankcase Ventilation Oil Separator

• If smoke is visible
Repair or replace the affected clamp, gasket, seal or component as necessary and repeat steps 4 and 5.

• If smoke is not visible

6. All OK