Charge Air Cooler Pressure check

i dont think you have a Air cooler problem if you changed it 2 years ago, maybe you have a clogged radiator?what truck do you have?

 

any regular car dealership will have a smoke machine for checking vacuum lines. i would call a couple and ask if they have a smoke machine.
find machine. take your air filter out. put it in a trash bag( plastic). then put the air filter back in. then hook up smoke machine to any of the intake lines on the air system. start thesmoke machine and watch the CAC for any smoke leaking out. if there is leaking smoke CAC is bad.
also while the smoke machine is hooked up too the air system, inspect all the parts for any other leaks. the smoke will just be pouring out if so.
this test blows the pressure test away
snap on sells a smoke machine for a grand. do CAC tests in truck stops for 40 bucks a shot, pay for machine. just saying

 

I bought plumbers 4" pipe plugs. Drilled a small hole in one of them and put a rubber tipped blow gun in it. Shoot some air in and listen for leaks.

 

take a 8" length of 4" exhaust pipe
stand it on a piece of 1/8" steel weld around it
torch cut around that
repeat on the other side
on 1 end drill a hole and weld a 1/2" union over it
get a small regulator and install in the union
pressure check your welds
cut the exhaust pipe in half
weld a bead around the pipes open end to keep the hoses form blowing off during testing (just clamping will not hold)
smooth it up with a grinder and then clean it up.
ready to use!

 

I am trying to upload pic's of my cac tester, but it say's image too large?

 

this size pipe fits snug into the air hose just next to the turbo, have to take turbo horn off. I just use clamp off hose around pvc. testing this way, I found a leak in my manifold where the boost sensor is mounted, the -o- ring was leaking bad, also if you put air in the sys this way you can find much more leaks, than when taken off truck to test, another example where only this type test will do... put air in sys & take off your oil filler cap. put your ear close, if you hear air, you have a leak bypassing your compressor. this is easy to fix with out doing anything with compressor. just plug manifold where the compressor gets it's air, eliminate the hose & put a filter kit on compressor to pull outside air. no hose to leak or break, cause if it did, you would lose air pres plus boost pressure. these 2 leaks I found on my truck this way. to me the manifold hose elimination is a good thing to do regardless.