7
TESTING FOR LEAKS
Follow all Redline Detection procedures for installation, testing and use of HD PowerSmoke™
Intake System Leak Testing
This test will find any leaks in ducting, charged air cooler, turbocharger, intake manifold, throttle body,
seals, gaskets, hoses, etc.
Seal off intake system by installing Power INTAKE™Adapters (see instructions) into intake ducting after air cleaner box. Begin
a 15-minute vapor cycle and pressurize entire system with vapor at 5 PSI (0.35 BAR) while inspecting for leaks using provided
halogen inspection light. If no leaks are present, increase pressure to 10 PSI (0.7 BAR) to observe leaks. Retest after repairs
are performed to confirm proper repair and seal.
Exhaust System LeakTesting
This test will find any leaks in exhaust tubing, clamps, flex pipe, muffler, diesel particulate filter,
turbocharger, exhaust manifold, etc.
Seal off exhaust system by installing Power INTAKE™Adapters (see instructions) into exhaust pipe. If using inside exhaust
stack use the exhaust retention hoop to keep Power INTAKE™Adapters from falling inside exhaust stack. Exhaust Particulate
Filter or Catalytic Convertor may not allow visible vapor to pass through because the particulates get trapped. In that case
you may use block off coupler to convert Power INTAKE™Adapters into a block off adapters while injecting smoke into the
system using the Temperature Sensor Port Adapter, Delta P Sensor Port Adapter, DPF Port Adapter, NOx Sensor Port Adapter
or Particulate Sensor Port Adapter. These particular port adapters give you a great amount of flexibility in testing all areas of
the exhaust system. Retest after repairs are performed to confirm proper repair and seal.
Combination Intake / Exhaust Testing
Some vehicles allow for a single procedure to test the entire intake and exhaust system at one time.
Many engine systems can be tested from the air box to the tip of the exhaust completely in a single test. To do so, install
Power INTAKE™Adapters (see instructions) into intake ducting after air cleaner box AND install Power INTAKE™Adapters
(see instructions) into exhaust pipe. Convert Power INTAKE™Adapters in exhaust system into a block off by installing block
off coupler. Inject vapor into the intake system through the Power INTAKE™Adapters. Pressurize entire system inspecting
for leaks. Note: Complete system testing can will occur when valve overlap is present or EGR valve is in open position. In
cases where valve overlap cannot occur or EGR may not be opened either manually or computer controlled, separate system
testing must be performed. Retest after repairs are performed to confirm proper repair and seal.
Cab Leak Testing
Test for driver cabin exhaust / carbon monoxide infiltration, wind and water leaks
Key on / Engine off, turn circulation fan to its highest speed making sure that the fresh air option is used (NOT recirculate). If
vehicle has dual air option, also initiate fan, selecting highest fan speed setting. The circulation fan produces a positive cabin
pressure. Make sure all windows and doors are completely closed. Install SmokeMeister™Wand to end of Vapor hose. Set
test pressure to 3 PSI (0.2 BAR). Make sure test is performed in a “still air” environment such as in a closed building. Using
SmokeMeister™Wand proceed around vehicle cabin laying down fluffy vapor on all seams, seals and joints looking for vapor
deflection from escaping air (leaks). Where vapor is deflected is a visual conformation of a leak. Seal leak and retest entire
cabin for further leaks. To check for doghouse engine cover leaks, turn off fans, install wand tip adapters into wand, and
inject vapor underside of doghouse while someone inside cabin looks for leaks. Retest after repairs are performed to confirm
proper repair and seal.
Coolant System LeakTesting
Cooling system leak testing can be performed two ways
Use HD PowerSmoke™ to quickly and easily find cooling system leaks either with decay testing or using visible vapor. First,
attach provided cooling system adapters to pressurized coolant bottle or radiator at cap. For decay testing, simply pressurize
coolant system with air-only to manufacturers recommended test pressure, typically 15 PSI (1 BAR). Turn off flow control
valve to lock out system and watch for decay. Inspect visually for leaking fluid. Alternatively, to perform leak test using vapor,
first drain the cooling system of all fluid. Introduce pressurized vapor in to cooling system at no more than the manufacturers
recommended test pressure and use inspection light to find leaks. Retest after repairs are performed to confirm proper repair
and seal.
IMPORTANT NOTE
Many leaks in heavy duty systems are considered “normal” or “within tolerance.” For example, a weep hole in a
muffler is acceptable. DO NOT assume every wisp of vapor represents a failing component. Check with vehicle manufacturer
before replacing suspected failed part.
!
!
