Charge Air Cooler Diagnosis

Engine Controls and Fuel - 3.0L LM2 Diesel | Diagnostic Information and Procedures | Document ID: 5227499 Diagnostic Instructions Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. Review Strategy Based Diagnosis for an overview of the diagnostic approach. Diagnostic Procedure Instructions provides an overview of each diagnostic category. Circuit/System Description The purpose of the Induction System Smoke Test is to aid in finding an air leak anywhere in the induction system including the crankcase ventilation system. Reference Information Special Tools GE 41413-SPT High Intensity White Light GE 41413-311 Brass Cone Adapter GE 41413-A Evaporative Emission System Tester (EEST) For equivalent regional tools, refer to Special Tools. Smoke Test Application

1. Ignition Off.
2. Place the air filter in a disposable plastic bag and secure it in the air cleaner housing to help prevent smoke leakage.
3. Remove a B193 Charge Air Cooler Temperature Sensor, refer to Charge Air Temperature Sensor Replacement.
4. Connect the GE 41413-A hose to the GE 41413-311.

Note

Wrap the GE 41413-311 with a layer of electrical tape to protect the threads in the inlet/outlet duct.

5. Insert the GE 41413-311 into the Charge Air Cooler (CAC) temperature sensor mounting boss on the CAC inlet or outlet duct.
6. Apply smoke continuously with the GE 41413-A while moving all duct work, pipes, and tubes.

Note

To improve the visibility of the smoke exiting the engine, illuminate the suspected leak area with the GE 41413-SPT and observe the area from different angles.

7. Verify smoke is not visible at the components listed below: Mass air flow sensor Air cleaner outlet duct Turbocharger air inlet adapter Crankcase depression regulator valve Intake manifold and gaskets Charge Air Cooler Hoses/Pipes/Tubes ⇒ If smoke is visible Repair or replace the affected gasket, seal or component as necessary and repeat steps 6 and 

⇓ If smoke is not visible 8. Refer to Component/System Leak Test and perform the Charge Air Cooler Diagnosis (Induction System Air Leak Test).