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Charge Air Cooler Tester

The Dura-Lite charge air cooler Tester-Kit is the fastest and most reliable on the market.

Find out if you have a leak in 20 minutes or less

With Dura-Lite’s charge air cooler Tester-Kit, testing your charge air cooler is as easy as checking your oil. The kit comes complete with everything you need to make pressure testing your charge air cooler safe and easy.

Your engine isn’t performing at its best.

We’ll Prove It.

These are the signs that your charge air cooler may be leaking and costing you $100K per year on fuel with a fleet of 15 vehicles!

Loss of engine power
Increased fuel consumption
Elevated soot levels in your oil
Premature piston, ring, and valve failure
Turbocharger or exhaust manifold failure
Elevated coolant temperatures

What’s included in our Tester-Kit?

  • The Tester-Kit comes complete with everything required to test the majority of charge air coolers.
  • The Tester-Kit components are made with high-quality materials and coatings to help resist corrosion and extend the longevity of the kit.
  • 1 Year Warranty.
  • Dura-Lite also offers replacement parts for its testing kit along with non-standard Rubber Test Plug sizes for special applications.

Tester-Kit Contents:

Description Item # Quantity
Tightening Handle DTK003 2
Flange Nut DTK039 2
Plug Stem Solid DTK002 1
Plug Stem With Male Connector DTK037 1
Plastic Washer (Test Plug Assembly) DTK005 4
2” [50.8mm] Washer (Round Center Hole) DTK006 2
2” [50.8mm] Washer (Oval Center Slot) DTK041 2
3” [76.2mm] Washer (Round Center Hole) DTK007 2
3” [76.2mm] Washer (Oval Center Slot) DTK040 2
Clamp Assembly DTK020 2
Gauge Assembly DTK026 1
Lubricant Bottle DTK029 1
Rubber Test Plug 2.500” [63.5mm] DTK008 2
Rubber Test Plug 2.750” [69.9mm] DTK009 2
Rubber Test Plug 3.000” [76.2mm] DTK010 2
Rubber Test Plug 3.250” [82.6mm] DTK011 2
Rubber Test Plug 3.500” [88.9mm] DTK012 2
Rubber Test Plug 3.750” [95.3mm] DTK013 2

Tester-Kit Accessories:

Description Item #
Rubber Test Plug 2.250” [57.2mm] DTK044
Rubber Test Plug 4.000” [101.6mm] DTK045
Rubber Test Plug 4.250” [108.0mm] DTK046
Rubber Test Plug 4.500” [114.3mm] DTK047
Rubber Test Plug 4.750” [120.7mm] DTK048
Plug Stem (Oval Center Slot) DTK001
Plug Stem With 2” [50.8mm] Washer (Oval Center Slot) DTK051
Plug Stem With 3” [76.2mm] Washer (Oval Center Slot) DTK052
Plug Stem Solid With 2” [50.8mm] Washer (Oval Center Slot) DTK053
Plug Stem Solid With 3” [76.2mm] Washer (Oval Center Slot) DTK054
Pressure Gauge (For Use With Pressure Regulator Item # DTK049) DTK021
Pressure Regulator DTK049
Valve Stem With Plastic Cap DTK024
Male Connector (For Use With Quick Coupler Item # DTK023) DTK004
Quick Coupler (For Use With Male Connector Item # DTK004) DTK023
Pressure Relief Valve (For Use With Pressure Regulator Item # DTK049) DTK025
Plastic Washer (Clamp Assembly) DTK061

How it Works

Step 1

Remove turbo hoses and clamps.

Step 2

Install Tester-Kit plugs and clamps. Mount gauge and double check system.

Step 3

Apply 30 psig of air. Remove air supply and check gauge. See chart (below) for Leak Down Rate Specifications. If leakage occurs beyond these specifications, it is strongly recommended that you replace your existing cooler with a Dura-Lite Evolution® Charge Air Cooler.

Step 4

Release air. Test is now complete.

Leak Down Rate Specifications

Caterpillar 5 psig in 15 seconds @ 30 psig
Cummins (ISB,ISC,N14) 7 psig in 15 seconds @ 30 psig
Cummins (ISX, M11) 5 psig in 15 seconds @ 30 psig
Detroit Diesel 5 psig in 30 seconds @ 30 psig
International 5 psig in 15 seconds @ 30 psig
Mack 5 psig in 15 seconds @ 30 psig
Mercedes 5 psig in 15 seconds @ 25 psig
Volvo 5 psig in 15 seconds @ 30 psig
* psig (pound-force per square inch gauge)

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

Stop wasting time and losing money

Get the Dura-Lite difference

If your charge air cooler is leaking, it’s time to replace it with the world’s best. Being an industry leader for over 30-years fuels our passion for creating superior products and allows us to proudly stand behind Evolution® charge air coolers with a 7-year, million-mile guarantee.

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We offer a large selection of charge air cooler and radiator solutions to meet your performance and durability needs.