You need to pressure test a leaking charge air cooler (CAC) to accurately confirm, locate, and measure the extent of any leak that may be present. Here's why it's essential:
Confirm the Presence of a Leak
- Small leaks often go unnoticed because they don’t leave a puddle under the vehicle and may not produce an audible hissing or visible symptoms.
- Pressure testing provides a controlled environment to identify even minor leaks that degrade engine performance.
Locate the Leak Precisely
Leaks may occur at:
- Welds or seams.
- Core tubes.
- End tanks.
- Hose connections.
- By applying pressure and using soapy water or leak detection fluid, bubbles will show the exact leak location.
Measure Leak Rate (Severity)
- Pressure testing lets you determine how severe the leak is.
- A rapid drop often means the CAC must be replaced.
Dura-Lite™ recommends testing to 30 psig for 15 seconds. Any drop is usually unacceptable for modern turbocharged diesel engines.
Prevent Engine Damage
If a CAC is leaking:
- Boost pressure is lost, leading to poor fuel economy, high exhaust temperatures, and power loss.
- Unfiltered air may enter the intake, risking damage to turbochargers or engine components.
- The engine emissions systems (like EGR and DPF) can also be negatively affected.
Avoid Unnecessary Replacements
- Pressure testing helps ensure that the CAC is truly the problem.
- You might find the leak is in a hose or clamp, saving you from replacing the whole cooler unnecessarily.
Summary:
Pressure testing a CAC is the only accurate and scientific way to assess system integrity. It protects your engine, turbo, emissions system, and fuel economy, and helps you avoid expensive guesswork.
Charge Air Cooler Pressure Tester
The Dura-Lite Charge Air Cooler (CAC) Pressure Tester-Kit™ is a diagnostic tool used to check the integrity and performance of a charge air cooler system, especially for diesel engines in trucks, buses, and heavy machinery. It helps detect leaks, pressure loss, or damage to the charge air cooler, which is critical for maintaining engine efficiency, fuel economy, and emissions compliance.
How Do You Pressure Test a CAC
Here's a helpful video that demonstrates how to use the Dura‑Lite Charge Air Cooler (CAC) Tester Kit step-by-step. It walks through:
- Installing rubber plugs on the inlet/outlet ports.
- Securing clamps and attaching the pressure gauge.
- Pressurising and then observing if the pressure holds.
- Checking the pressure drop to identify leaks.
CAC Test Kit
The Dura-Lite CAC Tester-Kit is designed and manufactured to be used to pressure test the charge air cooler safely and efficiently.
The kit comes complete with everything required to pressure test most charge air coolers, without removing the CAC from the vehicle, usually in less than 20 minutes. 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.
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