TESTING THE CHARGE AIR COOLER IN A THOMAS SCHOOL BUS WITH A CAT 3116 DIESEL ENGINE.

Diesel engines have a charge air cooler located in front of the radiator and has turbocharged air running through it entering the engine intake system. The engine fan cools the charge air cooler creating more air density which in turn increases the volume of air entering the engine and improves diesel engine performance.
We had a leaking radiator so the charge air cooler had to be removed making the testing process much easier. To test, just plug both ends and install an air pressure regulator but don't go over 20 p.s.i . Soapy water sprayed on the core will reveal any leaks which can be patched up with JB WELD but the core should be sent out for repair. We deal with a Radiator repair shop in Alberta who repair our cores for half the price of a new unit.
In a previous post I emphasized the power loss you would experience if the charge air had a leak which of course would drop your turbo boost pressure below maximum. In drier climates this charge air deterioration problem will not occur as often since our BC roads are sprayed with calcium chloride which is harsh on vehicles especially aluminum parts installed on diesel engines.