I've been trying to figure out why I cant build boost past 26 psi. So I decided to check the intercooler for leaks (plastic 05) I can't see any visual cracks but I can hear what sounds like a possible air leak. Is there a way I can check for cracks I can't see? Can I use soapy water and look for the bubbles? Of is there a chance of water entering the air flow to the engine?

 

Try pressurizing the induction tract with the engine off - so it's quiet enough to pinpoint the leak - by using compressed air.

Your early '05 with the cheapo plastic-tanked CAC is living on borrowed time.

 

You can cap it off and use compressed air to pressurize it. Since it is pushing air out I wouldn't think it would cause an issue. Just don't soak it.

 

soapy water will work a little water will not hurt anything in the motor.just remember the motor has to be under a load to build boost

 

Even at high idle I can hear the leak. How do I pressurize the intercooler itself with an air compressor after disconnecting and capping everything?

 

MAke a cap out of PVC to install in the intake tube. Install an air chuck into center of cap. Use a regulated air line and crank it down real low. Around 10 PSI. Plug it into air chuck on cap. Test away.

 

FWIW, I blew out the side of my intercooler, 05 as well. Put in a BD intercooler. Works well now, no issues and this thing is pretty stout.

 

I used a pvc fitting, screwed a cap on, then threaded a air line fitting into the cap. You can use a 4" to 4" rubber coupler to connect the pvc stuff to your turbo inlet or intake tube.

If it is indeed cracked, I've got an all metal 3rd gen intercooler that I don't need. Shoot me a PM if you end up needing one.