Supercharger Intercooler Pressure Testing

Special Tools

• EN-48974:  Adapter Kit
• J 46091:  Charge Air Cooler Tester

  For equivalent regional tools, refer to Special Tools .

Fig 1: Identifying Charge Air Cooler Tester Components
Courtesy of GENERAL MOTORS CORP.
WARNING: Do not apply greater than 69 kPa (10 psi) to the supercharger intercooler, this may damage the charge air cooler and other internal components within the intercooler.
1. Rotate the regulator knob (3) counterclockwise until stop to reduce pressure to 0 kPa (0 psi).
2. Connect the J 46091-1 to a shop air source (1).
Fig 2: Intercooler Water Manifold, Special Tool Adapter Hose, Clamps & Cap
Courtesy of GENERAL MOTORS CORP.
3. Install the EN-48974:  Kit adapter hose (1), cap (2) and clamps (3) to the coolant inlet and outlet connections of the intercooler water manifold. Tighten the clamps until snug.
Fig 3: View Of Kit Adapter Hose
Courtesy of GENERAL MOTORS CORP.
4. Install the J 46091-1 to the EN-48974:  Kit adapter hose.
5. Rotate the knob of the regulator slowly clockwise to increase pressure.
NOTE: The gauge value should not exceed 69 kPa (10 psi). Adjust the pressure regulator as required.
6. With the intercooler pressurized to 69 kPa (10 psi) maximum, close the air inlet valve of the J 46091-1.
7. Inspect for a drop in air pressure on the gauge.
   • If a drop in pressure is noted, inspect for leaks at the tool connections, the charge air coolers, service bleed ports, assembly plant fill port, and water manifold-to-charge air cooler seal locations.
   • If no drop in pressure is noted, the intercooler can be installed onto the engine assembly.