A pressure test is the most reliable way to determine whether a charge air cooler is leaking. Dura-Lite's Tester-Kit™ makes the process straightforward and can typically test a CAC in 20 minutes or less.

Follow these four basic steps:

Step 1: Remove the turbo hoses and clamps.

Ensure the engine is turned off, and the charge air cooler is cool. Disconnect the relevant hoses and clamps to access the CAC inlet and outlet. Check that the connections are clean and free from debris.

Step 2: Install the test plugs and safety clamps.

Select the correct rubber test plugs for your cooler's openings. Fit the plugs, safety clamps, gauge, and associated components securely, then double-check the connections before introducing compressed air.

Step 3: Apply pressure and check for leaks.

Using the Dura-Lite Pressure Gauge Assembly, apply 30 psi of air for typical heavy-duty applications, provided this matches your vehicle manufacturer's specifications. Disconnect the air supply and monitor the gauge for pressure loss over the specified period. Compare the result with your manufacturer's leak-down rate specification for the engine in reference.

Step 4: Release the air.

Carefully release all remaining pressure before removing the plugs and clamps. If the pressure loss exceeds the allowable leak-down rate specification, investigate the cause, and replace the faulty cooler as required with a Dura-Lite Evolution CAC.

Always follow the vehicle manufacturer's testing specifications and the instructions supplied with the kit. Never exceed the permitted pressure.

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