Charge Air Cooler Diagnosis

Charge Air Cooler Diagnosis

Diagnostic Instructions

* Perform the Diagnostic System Check - Vehicle Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
* Review Strategy Based Diagnosis Strategy Based Diagnosis for an overview of the diagnostic approach.
* Diagnostic Procedure Instructions Diagnostic Procedure Instructions provides an overview of each diagnostic category.

Circuit/System Description

The purpose of the charge air cooler smoke test is to aid in finding an air leak between the throttle body and the turbocharger.

Reference Information
Schematic Reference

Engine Controls Schematics (LUJ) [1][2]Electrical Diagrams
Connector End View Reference

Component Connector End Views Sunshade - Left (D6I)
Description and Operation

* Turbocharger System Description (LUJ) Description and Operation
* Boost Control System Description (LUJ) Description and Operation

Control Module References Control Module References for scan tool information
Special Tools

* J 4143-100 - Evaporative Emissions System Tester
* J 4143-200 - Evaporative Emissions System Tester
* J 4143-SPT - High Intensity White Light
* For equivalent regional tools, refer to Special Tools Tools and Equipment.

Smoke Test Application

Note: To operate the EVAP tester, refer to J 41413-200 (J 41413-100) Evaporative Emission System Tester operation manual.

1. Perform a visual inspection of all of the turbocharger components, including raising the vehicle for an underneath inspection.
2. Verify the tightness, fit, and proper connection of all hoses, pipes, clamps, charge air cooler, and the turbocharger.
3. Place the air filter in a disposable plastic bag in the air cleaner housing to help prevent smoke leakage.
4. Using the appropriate adapter, connect the J 41413-200 (J 41413-100) Evaporative Emission System Tester to the vehicle at the charge air bypass valve solenoid hose that leads to the charge air cooler outlet pipe.
5. Apply smoke continuously with the J 41413-200 (J 41413-100) Evaporative Emission System Tester while manipulating and applying pressure by hand to all hoses, pipes and the charge air cooler.
6. To improve the visibility of any smoke exiting the system, observe all of the turbocharger components from different angles.

• If a leak is detected, correctly position, tighten, repair, or replace the component as necessary.

Repair Instructions

Perform the Diagnostic Repair Verification Verification Tests after completing the diagnostic procedure.