how to test for intercooler leak? - Ford Powerstroke Diesel Forum
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post #1 of 4 Old 02-01-2010, 07:38 AM Thread Starter
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how to test for intercooler leak?

Recently bought my 2000 F250 with 145k miles. The truck had left front end damage that I've repaired. The driver side intercooler connector boot had a tear in it, so i replaced it (the one near the air cleaner). That improved power, and improved gas mileage a little (15 mpg to 16 mpg hiway at 2000 rpm). I'm hoping for better mileage and more power. Truck is bone stock. When going up hill at all, the mileage goes down to about 11 mpg - i'm thinking i'm losing power when the turbo kicks in, so want to check for addtl intercooler leaks.

How can I check the pressure in the intercooler lines to see if there is still a leak? I've seen mention of doing a leak test by installing a tire valve and filling with air, then checking to see if it's holding pressure, but I can't seem to find a "how to" to do this. Can anyone give me a step by step on how to do this?

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post #2 of 4 Old 02-01-2010, 01:37 PM
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Go to DieselSite and pick up one of their Boost Leak Detectors. Just remove your intake tube going into the turbo and mount it up. Get your air hose and fill it up to whatever the recommended psi is and listen for leaks. It is a great tool to have and not expensive at all.
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post #3 of 4 Old 02-01-2010, 05:12 PM
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So this unit hooks into the the turbo intake side where the air filter tube connects to the turbo?

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post #4 of 4 Old 02-01-2010, 06:33 PM
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Correct.

You can make one pretty easily if you can weld, get a short chunk of 4" exhaust pipe, use it as a template to cut out a circle of sheet metal to use as a pipe cap, weld the circle onto the small section of pipe, drill the center for a compressor male nipple, get a steel nipple and weld that in the center of the pipe cap, turn your compressor down to 25psi and your done! Might want to either roll a bead into the open end or lay a weld to keep it from blowing off the rubber intake hose at pressure.

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