The Dura-Lite™ Charge Air Cooler Tester-Kit™ is a tool designed to leak test charge air coolers (CACs) used in turbocharged diesel engines. It helps to detect leaks and pressure losses, which can significantly impact engine efficiency, power output, and fuel economy.

How the Dura-Lite Charge Air Cooler Tester Works:

Sealing the Charge Air Cooler

The Tester-Kit includes expandable rubber seals (also called plugs) that are inserted into the charge air cooler inlet and outlet ports.

These seals prevent air from escaping except through leaks.

Pressurizing the System

Compressed air is introduced into the CAC using a regulated air supply (usually from a shop compressor).

The system is gradually pressurized to a set level (typically 35 psig for most applications).

Leak Detection

The pressure is monitored using a built-in gauge.

If the pressure drops over time, it indicates a leak.

Assessing Performance

A properly functioning charge air cooler should maintain pressure for at least 15 seconds without significant loss.

Any pressure drop beyond the allowable limit indicates a need for repair or replacement.

Video on how to use Dura-Lite’s Charge Air Cooler Tester-Kit

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