Charge Air Cooler Test: A Step-by-Step Guide

A charge air cooler (CAC) pressure test helps diagnose leaks to maintain optimal engine performance. Follow these steps:

Equipment Needed:

  • Dura-Lite Tester-Kit.
  • Compressed air source.

Pressure Test Procedure:

  1. Preparation
  • Ensure the CAC is cool to the touch.
  • Disconnect the CAC hoses from the intake and exhaust connections.
  • Clean all connections and surfaces thoroughly.
  1. Pressure Test
  • Install Tester-Kit plugs and clamps.
  • Mount gauge and double check system.
  • Apply 30 psig of air. Remove air supply and check gauge.
  1. Leak Detection
  • See chart (below) for Leak Rate Specifications.
Caterpillar 5 psig in 15 seconds @ 30 psig
Cummins (ISB, ISC, N14) 7 psig in 15 seconds @ 30 psig
Cummins (ISX, M11) 5 psig in 15 seconds @ 30 psig
Detroit Diesel 5 psig in 30 seconds @ 30 psig
International 5 psig in 15 seconds @ 30 psig
Mack 5 psig in 15 seconds @ 30 psig
Mercedes 5 psig in 15 seconds @ 25 psig
Paccar 5 psig in 15 seconds @ 30 psig
Volvo 5 psig in 15 seconds @ 30 psig

* psig (pound-force per square inch gauge)

  • If leakage occurs beyond these specifications, it is strongly recommended that you replace the existing cooler with the Dura-Lite Evolution® charge air cooler.
  • Release any remaining air.
  • The test is now complete.

* These instructions are for reference purposes only. The actual testing procedure must be in accordance with instructions supplied in the Tester-Kit.

  1. Safety Considerations
  • Wear protective eyewear.
  • Follow manufacturer guidelines.
  • Consider professional inspection if unsure.

Regular pressure testing ensures optimal engine cooling and performance.

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