Intercooler pressure check

[SteveE]

My boost levels were not up to snuff so I made a couple of plugs to check intercooler and hoses.
Would not hold over 20 psi because of all of the leaks in the system, holds over 35 psi now.
Used soapy water at intercooler connections to locate leaks, at lot easier than trying to find them with the engine running and up to boost. Steve 2001. 5 QC LB 4X4 ETH/DEE
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[This message has been edited by Stevee (edited 05-15-2001). ]

 

[Tom C]

Stevee, What did you use to make the plugs?
Did you put one plug at the turbo end and one on the intake horn end?

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2001. 5 2500 4X4, QC, Auto, 3. 54 LSD, SLT, SWB, DD1's, EZ, DTT VB & TC, Westech Boost/EGT gage, Trailer, Camper & Snow plow Packages, White, 35k# Cody Hitch, 20' Gooseneck Lowboy flat-bed Trailer.
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1975 Toyota Landcruiser, ARB Air lockers Front & rear, 400 Small Block, SM420 4spd, Stock LC transfer case with 2 or 4 high and 2 or 4 wheel drive Low gears, 15. 5x36" Radial swamper on 12" rims, Custom front & rear bumpers, Roll Cage, Warn 8274 8000# winch, 2. 5" spring lift, 2" body lift. Premier on-board power welder, on-board air, 4-wheel power disk breaks, power steering, Lot of fun.

 

[SteveE]

I used a piece of driveline that had been discarded, 3 inch, welded end caps on, then tapped for valve core from a mag wheel.
Plugged in at intake and turbo ends.
Steve

 

[MCummings]

BOY!

Looks like those rubber boots are going to BLOW UP!!

How did you manage to pressure up the system?
and How did you fix the leaks?

MerrickNJr

 

[SteveE]

The hoses are at 35 psi in the pictures, and yes, they look like they are ready to blow.
Had to rough up the paint with sandpaper to get a good seal.
Used an air chuck just like I was filling tires... added air, checked pressure, found leak with soapy water in a spray bottle. When I first started it sounded like a bagpipe.
Steve

 

[tobaccogrower]

i've seen a good method:
buy a 5 inch pvc end cap for pipe at home depot and tap a air line fitting in the square part of the cap. then take the intake hose off the air box then put the cap in the end of the hose and tighten the clamp. set the regulator at whatever boost you can achive, then plug in the air line. MASSDIESEL used this method on my truck and it worked very well..... james...

 

[MCummings]

So... .
How'd you fix the holes ?
I think I am going to try this on my truck.

MerickNJr

 

[SteveE]

Originally posted by BOMBER_101:
So... .
How'd you fix the holes ?
I think I am going to try this on my truck.

MerickNJr

Didn't have HOLES, just leaks between the rubber boots and intercooler and black pipe.
Removed boots where they were leaking and roughed up the paint with sandpaper put back together and tighten. Leaks were not apparent until over 20 psi was applied.
Steve

 

[MCummings]

Oh.

Cool. glad you fixed 'em.

I think I'll BOMB My intercooler connectors too.

MerrickNJr