A failing charge air cooler (CAC) can significantly impact your vehicle's performance and lead to costly repairs if left unchecked. Recognizing the warning signs early can save you time and money.
Key Symptoms of a Charge Air Cooler Leak:
- Reduced Engine Performance
A leaking CAC reduces air pressure, causing decreased acceleration and overall engine power. You'll notice sluggish response and lower fuel efficiency.
- Unusual Whistling or Hissing Sounds
Pressurized air from the turbo that escapes through small leaks creates distinct sounds, especially during acceleration or under engine load. These noises indicate potential turbo system compromise.
- Elevated Soot Levels In The Oil
When a CAC leaks, less air from the turbo makes it to the engine. This causes incomplete combustion and results in an elevated level of soot in the oil and exhaust, and an increase in DPF regenerations.
- Increased Exhaust Smoke
A compromised charge air cooler will cause excessive dark exhaust smoke, signalling it is leaking.
- Check Engine Light Activation
Significant turbo system leaks trigger sensors, causing the check engine light to illuminate and potentially generating diagnostic trouble codes.
Professional inspection is crucial when experiencing these symptoms. Early detection prevents increased fuel consumption and maintains optimal vehicle performance.
Charge Air Cooler Tester
The Dura-Lite™ Tester-Kit™ is designed and manufactured to be used to pressure test charge air coolers safely and efficiently. The kit comes complete with everything required to pressure test most charge air coolers. With the Dura-Lite Tester-Kit, testing the charge air cooler will become as automatic as checking the oil and will give you confidence in knowing that an engine is performing at the required level.
The Tester-Kit components are made from high quality materials and coatings to help resist corrosion and extend the longevity of the kit.
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:
- 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.
- 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.
- 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.
- Safety Considerations
- Wear protective eyewear.
- Follow manufacturer guidelines.
- Consider professional inspection if unsure.
Regular pressure testing ensures optimal engine cooling and performance.
Learn how to use Dura-Lite’s Charge Air Cooler Test Kit
Buy a Dura-Lite Charge Air Cooler Test Kit:
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