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.
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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 |
|---|---|---|
| Plug Stem (Oval Center) With Male Connector | DTK037 | 1 |
| Plug Stem Solid (Oval Center) | DTK002 | 1 |
| 2” [50.8mm] Washer (Oval Center Slot) | DTK041 | 2 |
| 3” [76.2mm] Washer (Oval Center Slot) | DTK040 | 2 |
| 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 |
| 2” [50.8mm] Washer (Round Center Hole) | DTK006 | 2 |
| 3” [76.2mm] Washer (Round Center Hole) | DTK007 | 2 |
| Plastic Washer (For Use With Tightening Handle Item # DTK003 and Flange Nut Item # DTK039) | DTK005 | 4 |
| Tightening Handle | DTK003 | 2 |
| Flange Nut | DTK039 | 2 |
| Clamp Assembly (Includes Plastic Washer Item # DTK061) | DTK020 | 2 |
| Gauge Assembly | DTK026 | 1 |
| Lubricant Bottle | DTK029 | 1 |
| Tester-Kit Instructions | W-0038 | 1 |
| Product Registration/ Warranty Card | 1 |
Tester-Kit Accessories:
| Description | Item # |
|---|---|
| Plug Stem (Oval Center) | DTK001 |
| Male Connector (For Use With Quick Coupler Item # DTK023) | DTK004 |
| Plug Stem Solid (Oval Center) | DTK002 |
| 2” [50.8mm] Washer (Oval Center Slot) | DTK041 |
| 3” [76.2mm] Washer (Oval Center Slot) | DTK040 |
| Rubber Test Plug 2.250” [57.2mm] | DTK044 |
| Rubber Test Plug 2.500” [63.5mm] | DTK008 |
| Rubber Test Plug 2.750” [69.9mm] | DTK009 |
| Rubber Test Plug 3.000” [76.2mm] | DTK010 |
| Rubber Test Plug 3.250” [82.6mm] | DTK011 |
| Rubber Test Plug 3.500” [88.9mm] | DTK012 |
| Rubber Test Plug 3.750” [95.3mm] | DTK013 |
| 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 |
| 2” [50.8mm] Washer (Round Center Hole) | DTK006 |
| 3” [76.2mm] Washer (Round Center Hole) | DTK007 |
| Plastic Washer (For Use With Tightening Handle Item # DTK003 and Flange Nut Item # DTK039) | DTK005 |
| Tightening Handle | DTK003 |
| Flange Nut | DTK039 |
| Clamp Assembly (Includes Plastic Washer Item # DTK061) | DTK020 |
| Plastic Washer (For Use With Clamp Assembly Item # DTK020) | DTK061 |
| Pressure Regulator | DTK049 |
| Pressure Gauge (For Use With Pressure Regulator Item # DTK049) | DTK021 |
| Valve Stem With Plastic Cap | DTK024 |
| Pressure Relief Valve (For Use With Pressure Regulator Item # DTK049) | DTK025 |
| Quick Coupler (For Use With Male Connector Item # DTK004) | DTK023 |
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 |
| Paccar | 5 psig in 15 seconds @ 30 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.
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