Test Procedure

Intake System 

1. Remove the air duct from the air cleaner case. Refer to Exploded View .
2. The following portion of this procedure will help diagnose an intake air system leak.
   1. Install Inlet Adapter (A) inside the air duct (1) and tighten clamp.

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      Inlet Adapter

      :-- - (96-0109)

   2. Remove the tail pipe. Refer to Exploded View .
   3. Install Adapter (A) into the end of the decomposition tube and SCR catalyst assembly (1).

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      Adapter

      :-- - (95-0086)

      NOTE: Leaving the tail pipe connected to the decomposition tube and SCR catalyst assembly creates a higher chance of leaks from that connection and may reduce the ability to find leaks at other locations.
3. Pinch off the crankcase breather tube (1) with a suitable tool (A).

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   CAUTION: Use only suitable tools designed to pinch off rubber hoses to prevent damage to the tube.
4. Loosen the oil fill cap. Leave it resting on the oil fill opening.
   CAUTION:

   • If the oil fill cap is not loosened the crankcase pressure will exceed the designed limits of some of the oil seals for the crankcase and will damage the seals.
   • The oil cap resting in the oil fill opening prevents any unwanted debris or tools from entering the engine.
5. Connect a compressed air source to the Dual Purpose Diagnostic Leak Detector Tool and connect hose end (B) to either Inlet Adapter (A) in the air duct or the decomposition tube and SCR catalyst assembly.

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   Dual Purpose Diagnostic Leak Detector Tool - (hose end B)	:-- - (95-0130)
   Inlet Adapter (A)	:-- - (96-0109)

   NOTE:

   • If testing from the pressure fitting in air duct install block off coupler (B) onto adapter (A) as shown.

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   • If testing from the pressure fitting in the decomposition tube and SCR catalyst assembly, install block off coupler (A) onto inlet adapter (B) as shown.

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6. Use the Dual Purpose Diagnostic Leak Detector Tool to regulate air pressure to no more than 69 kPa (0.7 kg/cm ² , 10 psi) of pressure into the system.
   CAUTION: Exceeding air pressure specified in this procedure could result in engine damage.
   NOTE: Smoke from the Dual Purpose Diagnostic Leak Detector Tool may be used to identify air leaks in the system.

   Dual Purpose Diagnostic Leak Detector Tool

   :-- - (95-0130)

7. Listen for air leaks throughout the turbocharger, charge-air cooler, exhaust and aftertreatment systems. Be sure to check coupler connections, sealing surfaces and gaskets. A solution of soap and water can be used along with smoke from the Dual Purpose Diagnostic Leak Detector to find small leaks.
   NOTE:

   • It may be necessary to allow a few minutes until pressure fills the system.
   • The flow meter on the Dual Purpose Diagnostic Leak Detector Tool is a good indication of leaks in the system. Small leaks will show up as low flow and larger leaks will indicate as a higher flow rate on the Dual Purpose Diagnostic Leak Detector.

   Dual Purpose Diagnostic Leak Detector

   :-- - (95-0130)

8. If leaks are identified under the intake manifold it will be necessary to remove the intake manifold. Refer to Removal and Installation .
   CAUTION: Exceeding air pressure specified in this procedure could result in engine damage.
   NOTE:

   • The system will not hold pressure. Some air leaks to the crankcase will occur through the turbocharger oil seals. Some leaks are acceptable and will be audible.
   • Small leaks at the rotary turbine control shaft are acceptable.
   • Once the intake manifold is removed the pressure can be applied again to allow for further inspection.
9. After testing is complete, installation is in the reverse order of removal.
   NOTE: Operate the engine and check for leaks.

Exhaust System 

1. The following portion of this procedure will help diagnose an exhaust system leak. Leaks in the exhaust system will cause the turbocharger to operate at a lower speed, reducing the amount of air going to the cylinders during engine operation.
   NOTE: Leaks can be identified by noise or discoloration caused by escaping hot gases.
2. Inspect the following locations for exhaust system leaks:
   • Exhaust manifold collector pipe gasket (2), exhaust transfer tube gasket [bank 1 (4)], exhaust transfer tube gasket [bank 2 (3)] and EGR bypass tube gasket (1).

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   • Exhaust manifold gasket (1) and exhaust transfer tube gasket [bank 2 (2)].

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   • Exhaust gas recirculation (EGR) components:
     • Exhaust transfer tube (bank 1) gasket (1).

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     • EGR valve gasket (2).
     • EGR cooler outlet O-ring connection (A).
   • Exhaust pressure sensor tube (2) to intake manifold (1) connection (A) and exhaust pressure sensor tube (2) to exhaust transfer tube [bank 2 (3)] connection (B).

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