Engine/Transmission (1994 - 1998) Intercooler/intake leak

[McLaughlin]

What is the best/perferred way to check the intercooler and intake system for a small leak and is there a good way to tell if the fuel return lines are leaking air? I've posted before that I'm getting poor fuel economy and have verified that I'm only getting about 12 mpg(used to get 17+). My daughter was following me yesterday and said that every time I was idling at a stoplight, there was visible smoke and the smell of diesel from the truck. I've replaced the fuel filter, drained the water fuel separator, had the timing checked (+15 degrees) and done a visual inspection of the hoses coupling to the intercooler. Problem is if I have a small hole in the hoses or the intercooler, I'm not sure I would have seen it.

 

[tareynolds]

check the rubber hoses that run to fuel tank, on the drivers side of the truck at the trans. bell housing, this is the most common problem that I have come across. they will let air enter the fuel system and cause this problem.

 

[BigBadDodge]

I found my intercooler was bad with this device I made, just hook a air hose to it and listen for the leaks. You can all the parts at your local hardware store.



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BBD

 

[Jim Fulmer]

I built one of those checkers but I put it in the top turbo to checkout the system. After it blew off at 60 psi..... against the shop wall I made a few changes... ... cool but freaky! Now I can check it at 80+ psi with no leaks..... but I do have a PDR cooler.



Jim

 

[BigBadDodge]

LOL Jim, my first attempt it blew off, fortunatly at way lower psi then yours did.



BBD

 

[McLaughlin]

I found my intercooler was bad with this device I made, just hook a air hose to it and listen for the leaks. You can all the parts at your local hardware store.



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BBD

Thanks I give it a try.

 

[McLaughlin]

check the rubber hoses that run to fuel tank, on the drivers side of the truck at the trans. bell housing, this is the most common problem that I have come across. they will let air enter the fuel system and cause this problem.

Is there anything in particular to look for other than cracking and abrasion?