Leak Testing
WARNING: This page is about a different car, the 2013 RAM 3500 HD and 2013 RAM 2500 HD. However, it is still accessible from the selected car via links, so may be relevant.
multimedia:A supplement to the article is available.
CAUTION:
The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the exhaust system.
- Raise and support vehicle.CAUTION:
The air pressure must not exceed 4 psi, otherwise engine damage can occur.
- Connect Tool (special tool #8404-ECT, Exhaust Cone, Truck), Exhaust Cone to Air Pressure Regulator (with hose) W-18-MIL-1146AS.
- Attach shop air to the air pressure regulator.
- Adjust the air pressure regulator to 4 psi
- Insert Tool (special tool #8404-ECT, Exhaust Cone, Truck), Exhaust Cone into the vehicle tail pipe.
- If the vehicle is equipped with dual exhaust, use Tool (special tool #8404-ECT, Exhaust Cone, Truck), Exhaust Cone with equipped attached plug. Plug one side of the dual exhaust pipe. Pressurize the other as described.
- Apply a mixture of MOPAR® Air Leak Detector to the following areas:
- - All welded joints from 6 inches rearward of the downstream NOx sensor forward
- - NOx sensor seal points
- - NOx sensor boss welds
- - Flange/joint connection(s)
- - Exhaust manifold to cylinder head connection(s)
- - EGR solenoid gasket base and tube seal points (if equipped)
- Watch for the Air Detector to bubble.
- Use the following definitions to help determine if system or component repair/replacement is necessary:
- Type 1 Leak is defined as a leak where very small foam like bubbles 1 mm (.039 in.) or less appear. Any Type 1 or greater leaks found in welded joints, NOx sensor seal points or NOx sensor boss welds must be repaired or the component must be replaced.
- Type 2 Leak is defined as a leak where larger bubbles 8 mm (.32 in.) or greater appear. Any Type 2 or greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections, or EGR gasket and tube seal points must be repaired or the components must be replaced.
| Leak Location | Repair required if results at 4 psi reveal bubble size: |
|---|---|
| Welded joints | Type 1 - 1 mm (.039 in.) or greater |
| NOx Sensor seal points | Type 1 - 1 mm (.039 in.) or greater |
| NOx Sensor boss welds | Type 1 - 1 mm (.039 in.) or greater |
| Flange/joint connections | Type 2 - 8 mm (.32 in.) or greater |
| Exhaust Manifold to cylinder head connections | Type 2 - 8 mm (.32 in.) or greater |
| EGR gasket and tube seal points | Type 2 - 8 mm (.32 in.) or greater |
| EGR cooler to exhaust manifold connections | Type 2 - 8 mm (.32 in.) or greater |
If a leak is found that matches the above definition, repair or replace the component as necessary.
Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.