How to diagnose a Blown Intercooler? - Ford Powerstroke Diesel Forum
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Old 08-27-2011, 10:18 PM
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How to diagnose a Blown Intercooler?

Im running out of small things to replace(boots and plastic duct) to find a boost leak.

Is there any way to check the intercooler for leaks while still on the truck?

Ive replaced all the boots(BD Kit with clamps and hair spray) and the plastic cold side pipe with the updated aluminum tube and im still getting a leak when I go over half throttle. Also replaced the de-gas cap just to make sure it wasn't something stupid, even though the one thats on there is fine.

Im pretty sure its my problem but not willing to spend the 500 dollars just yet LOL

Last edited by LvGolfer962; 08-28-2011 at 07:20 AM.
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Old 08-27-2011, 10:58 PM
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Take off the intake and hook up a air compressor.
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Old 08-28-2011, 06:07 AM
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Is the hiss so loud that you sound like a streetsweeper?
Have you had your turbo off recently?
You could try opening the hood, have someone "power brake" it and listen for where the leak is.
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Old 08-28-2011, 06:25 AM
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Quote:
Originally Posted by NYC F-350 View Post
Is the hiss so loud that you sound like a streetsweeper?
Have you had your turbo off recently?
You could try opening the hood, have someone "power brake" it and listen for where the leak is.
I wouldn't call it a street sweeper sound, I will try to and see if I can capture it on my camera

Tried the power brake but could not repeat the noise. The turbo has to be wound up to hear it, 3/4 to full throttle to duplicate.

The turbo along with a whole bunch of other parts were off 4-5 months ago for an egr cooler/oil cooler repair. I had a shop install my 4inch turbo back exhaust a few months ago but i have no idea if the turbo was moved for that
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Old 08-28-2011, 06:28 AM
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Check the y-pipe to turbo connection with a flashlight and mirror all the way around. Look for soot. Also check the expansion joints in the y-pipe for the presence of soot. Also check the exhaust manifold to up-pipe connections...You find soot and you found your problem. The issue would be pre-turbo if it is exhaust related.
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Old 08-28-2011, 08:36 AM
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if you can get a good look at the tanks on the intercooler a lot of times you can see the seal physically hanging out. it's just a light blue rubber gasket
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Old 08-29-2011, 04:22 AM
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Quote:
Originally Posted by NYC F-350 View Post
Check the y-pipe to turbo connection with a flashlight and mirror all the way around. Look for soot. Also check the expansion joints in the y-pipe for the presence of soot. Also check the exhaust manifold to up-pipe connections...You find soot and you found your problem. The issue would be pre-turbo if it is exhaust related.
I looked around the back firewall and didnt see any soot on the shiny insulation but that doesn't mean much, i think its going back to the shop to have them take a look at it.

Quote:
Originally Posted by sinner6.0L View Post
if you can get a good look at the tanks on the intercooler a lot of times you can see the seal physically hanging out. it's just a light blue rubber gasket
I read about the seals popping and its pretty hard to get a good look at the whole intercooler but what I could see it didnt look like any of the gaskets had popped out

Thanks guys
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Old 11-12-2012, 04:30 AM
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I think I may have blown mine, there is a lot of blow-by residue on the passenger side of the intercooler(below the cold side outlet), I cant make more than 22 lbs of boost, with the factory turbo and even after the new powermax....
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Old 11-12-2012, 05:17 AM
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With some exaust pipe, a lil welding and your old boots you can build a tester. Cap off one side, put a ball valve, shop air fitting and gauge in the other cap, put about 20psi shop air into it, close the ball valve, and watch the gauge, if it goes down pretty fast you have a leak.
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