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.

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