LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2006 >> Silverado 1500 HD, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1364 (Engine Controls And Fuel - 6.6L - Troubleshooting & Diagnosis) >> Charge Air Cooler Diagnosis (Full System Air Leak Test) >> Leak Test Results

Leak Test Results

WARNING: This page is about a different car, the 2009 GMC Sierra, 2009 GMC Cab & Chassis Sierra, 2009 Chevrolet Silverado, and 2009 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
  • An air leak that appears as small bubbles or foaming is normal.
  • Intake Air Heater gaskets that show a small leak or foaming is normal.
  1. With the air valve ON, the gage on the regulator assembly should read greater than 158 kPa (23 psi), and there should be no abnormal air leaks.
    • If the air pressure gage reads less than 158 kPa (23 psi) with constant air pressure applied, and audible air leaks are present, the leak test has failed. Perform the following procedure:
      1. Inspect for air leaks by listening for excessive hissing sounds.
      2. Inspect for air leaks by using a pump spray bottle to apply a soapy solution, while observing for excessive soapy bubbles at all of the following engine locations:
        • Charge air cooler pipes/hoses connections
        • Charge air cooler core
        • EGR valve gaskets
        • EGR valve cooler gaskets
        • Exhaust manifold gaskets
        • Turbocharger gaskets, inlet and outlet connections
        • Intake manifold gaskets
          • If any abnormal leaks are found, replace the affected gasket or component as necessary.
  2. Retest the engine system for air leaks. The gage on the regulator assembly should read greater than 158 kPa (23 psi), and there should be no abnormal air leaks.
    • If the gage reads less than 158 kPa (23 psi) with air valve ON, and audible air leaks are present, recheck for air leaks.
  3. If no other air leaks are found, assemble the vehicle. Remove the tester and adapters by performing the following procedure:
    1. Slowly bleed the air from the cooler by depressing the relief valve on the adapter.
    2. Remove the air hose, gage/regulator assembly, and both adapters.
    3. Connect the charge air hose to the turbocharger with the clamp and tighten the clamp to 8 N.m (70 lb in).
    4. Install the catalytic converter. Refer to Catalytic Converter Replacement (With LU3) or Catalytic Converter Replacement (With V8 Engine) or Catalytic Converter Replacement (With LMM) .
    5. Clear all DTC information with a scan tool.
scientia non olet · About LEMON Manuals