Intercooler: Testing and Inspection

Charge Air Cooling System Leak Testing (LSA)

Special Tools

* EN-24460-A - Cooling System Pressure Tester

* GE-47716 - Vac-N-Fill Coolant Refill Tool

* GE-47716-20 - Cooling System Fill Adapter

* GE-50389 - Coolant Pressure Test Quick Connector

* For equivalent regional tools. Refer to Special Tools Tools and Equipment.

Cooling System Leak Testing

Warning

Under pressure, the temperature of the solution in the radiator can be considerably higher, without boiling. Removing the radiator cap while the engine is hot (pressure is high), will cause the solution to boil instantaneously, with explosive force. The solution will spew out over the engine, fenders, and the person removing the cap. Serious bodily injury may result. Flammable antifreeze, such as alcohol, is not recommended for use at any time. Flammable antifreeze could cause a serious fire.

Warning

In order to help avoid being burned, do not remove the radiator cap while the engine and the radiator are hot. Scalding fluid and steam can be blown out under pressure if the cap is removed too soon.




1. Remove the CAC quick connect cap (1) and ensure there is adequate coolant within the CAC system.




2. Install Cooling System Pressure Tester Cap Adapter to EN-24460-A - Cooling System Pressure Tester.

3. Install the Vac-N-Fill Cap to the Cooling System Pressure Tester Cap Adapter.

4. Install the GE-50389 - Coolant Pressure Test Quick Connector to the Vac-N-Fill Cap.

5. Install the GE-47716-20 - Cooling System Fill Adapter to the GE-50389 - Coolant Pressure Test Quick Connector.

6. Remove the charge air cooling system cap from the fitting on the upper port of the supercharge.

7. Install the GE-47716-20 - Cooling System Fill Adapter in place the charge air cooling system cap. Ensure that the Cooling System Fill Adapter is firmly seated.

8. Apply 5 psi pressure to the charge air cooler system for at least 2 minutes.

9. Observe the gauge for any pressure loss and repair any leaks as required.