Sprinter 2500 L5-2.7L DSL Turbo (2003)
Intercooler: Testing and Inspection
DIAGNOSIS AND TESTING - CHARGE AIR COOLER SYSTEM - LEAKS
NOTE: Slight engine oil pooling in the charge air inlet hose IS NOT premature turbocharger failure. Slight pooling is the normal result of the
breather system. Test the air breather tube for normal operation by referring to the appropriate diagnostic manual.
Low turbocharger boost pressure and low engine performance can be caused by leaks in the charge air cooler or it's plumbing. The following
procedure outlines how to check for leaks in the charge air cooler system.
1. Loosen clamp and remove turbocharger to air inlet duct rubber sleeve from turbocharger.
2. Insert Special Tool 8442 Adapter into the rubber sleeve. Tighten existing clamp to 8 Nm (72 inch lbs.).
CAUTION: Do not apply more than 138 kpa (20 psi) air pressure to the charge air cooler system, sever damage to the charge air cooler system
may occur.
3. Connect regulated air supply to air fitting on Special Tool 8442 Adapter. Set air pressure to a Maximum of 138 kpa (20 psi).
4. Using soapy water check the air inlet ducts, rubber sleeves, charge air cooler and intake manifold for leaks.
