• | 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. |
• | EN-47603 Compression Gage Adapter |
• | J 46091 Charge Air Cooler Tester |
• | J-46091-10 Charge Air Cooler Tester Adapter |
Important: Some J 46091-1 regulators may have the adjusting knob riveted in place. The rivet head must be drilled out with a 5/16 inch drill bit before adjustment. Do not drill more than 1/8 inch in depth, or just enough to remove the rivet head. The rivet shaft does not have to be removed from the regulator.
Important: It is not necessary to remove the charge air cooler from the vehicle to perform this test.
Important: After removing the charge air cooler duct, cover the intake heater opening with tape in order to prevent entry of objects.
Tighten
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.
Important:
• After removing the charged air cooler duct, cover the turbocharger opening with tape 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.
Tighten
Torque the clamp to 8 N·m (70 lb in).
Caution: Refer to Charge Air Cooler Caution in the Preface section.
Caution: Refer to Charge Air Cooler Caution in the Preface section.
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.
If the pressure drop is more than 34 kPa (5 psi) in 15 seconds, the leak test has failed. Perform the following procedure:
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:
Tighten
Torque the clamp to 8 N·m (70 lb in).