A Dura-Lite™ Intercooler Test Kit, also known as a Charge Air Cooler (CAC) Test Kit, is a diagnostic tool used to check for leaks, pressure loss, or performance issues in an engine’s intercooler (charge air cooler) system.
The test kit allows technicians and truck owners to:
- Detect leaks in the intercooler or its connecting hoses.
- Verify that the charge air system can hold the correct pressure.
- Prevent loss of engine power.
- Improve fuel economy.
- Reduce excess exhaust emissions.
Dura-Lite’s well-known CAC Tester-Kit™ is an industry-standard product used by many fleets and service shops.
It’s designed to:
- Test CACs on or off the vehicle.
- Be compatible with various hose and pipe diameters.
- Ensure accurate detection of even small leaks that can impact performance.
How to Diagnose a Faulty Intercooler
Before you start - Kit and PPE
Kit checklist:
- Test plugs/ adapters for inlet and outlet.
- Pressure gauge with valve.
- Air hose/ fittings/ tire chuck.
- Soapy spray bottle (dish soap and water).
- Safety glasses.
- Hearing protection.
- Protective clothing.
Safety notes:
- Always follow the vehicle manufacturer’s leak down rate specification. Typical test pressure is 25-30 psig for most heavy-duty truck CACs but check the leak down rate specification for the vehicle you are working on.
- Over-pressurising is very dangerous and can cause serious bodily injury.
- Do not pressurize while the engine is running.
- Depressurize the system carefully before removing the test plugs and safety clamps.
View the Dura-Lite Intercooler/ Charge Air Cooler (CAC) Tester-Kit Video
The Dura-Lite CAC Tester-Kit is designed and manufactured to be used to pressure test an intercooler/ 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.
Cracked Intercooler Symptoms
- Loss of Power or Weak Acceleration.
The most obvious symptom.
Turbo boost pressure leaks through the crack, so less compressed air reaches the engine.
Feels like laggy throttle response or the truck struggles to climb hills or maintain speed under load.
- Increased Fuel Consumption
The ECM/ engine compensates for lost air by injecting more fuel.
Leads to noticeably reduced miles per gallon (MPG), especially under boost conditions (acceleration).
- Excessive Black Smoke.
Too much fuel and not enough air = incomplete combustion.
Black soot or smoke is emitted from the exhaust, particularly when accelerating.
- High Intake or Exhaust Gas Temperatures (EGT).
Because the turbo has to work harder to build boost pressure that escapes, intake air gets hotter.
This raises EGT, potentially harming pistons, valves, and the turbocharger over time.
- Whistling or Hissing Sounds.
Air escaping from a crack or hole often creates a distinct whistling, hissing, or chirping noise, especially under boost.
Often more noticeable during acceleration or when the turbo spools up.
- Oil Residue Around the Intercooler.
A cracked intercooler or leaking joint often shows oil mist or streaks around the damaged area.
Turbos naturally push a small amount of oil vapor through the intake - that oil then seeps out through cracks, leaving dark, greasy deposits.
- Overworked Turbocharger.
The turbo spins harder trying to compensate for lost pressure.
Can cause excess turbo noise, early bearing wear, or failure if ignored.
- Rough Idle or Misfires (in some engines).
Unmetered air entering or leaking out of the system affects the air-fuel ratio.
Causes uneven idle, hesitation, or misfire codes in some vehicles.
Understanding the symptoms of a cracked intercooler (charge air cooler) is key to diagnosing performance problems in turbocharged diesel trucks.
Common leak locations to inspect:
- Tube to header joints.
- Header to end-tank welds.
- Core tubes (cracks, corrosion, and punctures).
- Hose connections and hose clamps.
- Oil-soaked areas.
Intercooler Pressure Tester
You can buy a Dura-Lite Intercooler Pressure Tester online from one of our online stores.
The product is usually shipped the same day (if ordered before our cut-off time) from one of our strategically located, well stocked, Distribution Centers within the USA and Canada.
With our Intercooler Pressure Tester, testing your Intercooler will become as automatic as checking the oil and will give you confidence in knowing that your engine is performing at the required level.
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