I found part of my heat problem Saturday, intercooler is leaking in the lower right corner. Any of you guys tried dealing with Dura-lite here in Calgary? I know they make intercoolers for big stuff, gonna call them Monday and see what they say.I also ordered a new set of boots from Peak Friday.

 

Well...With the air leaking between my ears,I borrowed Mckee pressure device.I found one big hole in my truck.Boost air is leaking between the large snap ring and turbo charger.Also its leaking really bad at the clamp between the aluminum turbo outlet and the aluminum elbow connected the the boot.Now to figure out how to fix it.Any gaskets between the turbo and elbow??

 

Its an o-ring.

 

Thanks...Now I kind of remember that,not sure why its leaking past the snap ring also.....Time to get the big hammer out...Is that a o-ring I could get at Cummins???

 

probably, not 100% sure though.

 

The large snap ring on the turbo compressor housing? That leak may be hard to fix. You would have to disassemble the compressor housing from the turbo as there is an o-ring there as well. How bad is the leak on the compressor housing? I see that alot on industrial machinery and its typically not worth the cost of pulling the turbo down.

 

Yep...its leaking also at the large snap ring..The two leaks are bad enough that at 95 PSI at the tire valve, the max pressure in the system is 18 PSI.

 

Now look what i've started

 

Eek. Well I don't know what kind of flow a tire stem can handle, but that is a good sized leak. The o or rather square ring at the compressor nozzle should be fairly easy to replace.. The turbo.... How are you blocking off the turbo? Covering the intake filter side somehow?

 

We are charging the system from the intake side of the turbo J. just pulling off the hose from the bhaf or stock box and clamping in my "tester" .

 

What about the engine side? Do you pull the intake horn?

 

We left the intake horn on..and pressured up the system with the air filter removed...

 

Ok, so depending on the rotation stoppage of your engine, you could have a few intake valves open. But may not flow through the engine if the exhaust valves are not open (overlap). Interesting.

 

I never even thought of that, but mine was so obvious it wouldn't have mattered. I didn't hear any other spots, must have got lucky.I will make a plug for the other end when i drop the new cooler and boots in.

 

Depending on ring and valve seal condition, that could still be a good leak point. I remember Jeff had a big boost leak because of bad valve seals. Then that just bleeds into the crank case.

Are you guys doing it on a hot engine? Or if cold, might be worth adjusting all the valves so there is no preload on them.