Diagnosis And Testing - Charge Air Cooler System - Leaks

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Slight engine oil pooling in the charge air inlet hose IS NOT premature turbocharger failure. Slight pooling is the normal result of the breather system. Test the air breather tube for normal operation by referring to the appropriate diagnostic article.

Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or it's plumbing. The following procedure outlines how to check for leaks in the charge air cooler system.

Loosen clamp and remove turbocharger to air inlet duct rubber sleeve from turbocharger.
Insert Special Tool 9556 Adapter into the rubber sleeve. Tighten existing clamp to 8 N.m (72 in. lbs.).
Separate the breather hose at the breather heater and block off.
Remove the oil level indicator and block off tube.
CAUTION: Do not apply more then 0.6 bar (10 psi) air pressure to the charge air cooler system, sever damage to the charge air cooler system may occur.
Connect regulated air supply to air fitting on Special Tool 9556 Adapter. Set air pressure to approximately 0.6 bar (10 psi).
Using soapy water check the air inlet ducts, rubber sleeves, charge air cooler and intake manifold for leaks.