[Question] Turbo intercooler pressure testing -
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Turbo intercooler pressure testing -

  1. #1
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    Default Turbo intercooler pressure testing -

    I have a Race Aero twin turbo set-up and wish to pressure test the radiators.
    I am looking for the best way to pressure test it and find out if there is any leakage. Since I have never had intercooler apart, I think it is in my best interest to ask those who have.
    The engine is currently being rebuilt, so the intercooler is still attached to the manifold, but off the motor. I assume the intercooler needs to come apart in order to remove it from the manifold.

    My questions regarding testing the intercooler would be, does the front cover come off first or should the front cover remain attached and a device be made to pressure test the core with air pressure or can it even be done that way while still attached to manifold.
    Are there two radiators inside or one? When the front cover is removed, does the radiator(s) stay attached to the front cover or will it come off? The front cover has one water inlet and two water outlets, so what should I expect to find inside.
    As I mentioned earlier, I assume the intercooler is attached to the intake manifold inside, is that correct?

    I haven't done this before, so what do I need to be made aware of?

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    Platinum Member BigSteve's Avatar
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    Quote Originally Posted by jimsplace View Post
    I have a Race Aero twin turbo set-up and wish to pressure test the radiators.
    I am looking for the best way to pressure test it and find out if there is any leakage. Since I have never had intercooler apart, I think it is in my best interest to ask those who have.
    The engine is currently being rebuilt, so the intercooler is still attached to the manifold, but off the motor. I assume the intercooler needs to come apart in order to remove it from the manifold.

    My questions regarding testing the intercooler would be, does the front cover come off first or should the front cover remain attached and a device be made to pressure test the core with air pressure or can it even be done that way while still attached to manifold.
    Are there two radiators inside or one? When the front cover is removed, does the radiator(s) stay attached to the front cover or will it come off? The front cover has one water inlet and two water outlets, so what should I expect to find inside.
    As I mentioned earlier, I assume the intercooler is attached to the intake manifold inside, is that correct?

    I haven't done this before, so what do I need to be made aware of?
    I use to test the big diesel air to air inter coolers.Used the coupler hoses and clamps. We went to the hardware store and got some PVC pipe and end caps, put a fitting in it and throw in the tire water tank and looked for bubbles
    Last edited by BigSteve; 02-07-2013 at 07:05 PM.
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  4. #3
    Some guy obnoxious001's Avatar
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    Quote Originally Posted by jimsplace View Post
    I have a Race Aero twin turbo set-up and wish to pressure test the radiators.
    I am looking for the best way to pressure test it and find out if there is any leakage. Since I have never had intercooler apart, I think it is in my best interest to ask those who have.
    The engine is currently being rebuilt, so the intercooler is still attached to the manifold, but off the motor. I assume the intercooler needs to come apart in order to remove it from the manifold.

    My questions regarding testing the intercooler would be, does the front cover come off first or should the front cover remain attached and a device be made to pressure test the core with air pressure or can it even be done that way while still attached to manifold.
    Are there two radiators inside or one? When the front cover is removed, does the radiator(s) stay attached to the front cover or will it come off? The front cover has one water inlet and two water outlets, so what should I expect to find inside.
    As I mentioned earlier, I assume the intercooler is attached to the intake manifold inside, is that correct?

    I haven't done this before, so what do I need to be made aware of?
    The intercooler should be mounted to the manifold just like a carburetor,, with 4 studs and nuts. Once it's off the manifold, you will probably want to pressure test it as a unit. There are two radiators inside, once the cover is removed, there should be gaskets on both sides of the radiator flange.

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    Senior Member steveo143's Avatar
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    There are 2 cores inside. I remove them and made a plate with a shraeder valve to cover 1 radiator, give it 40/50 #s and put it the pool to check for leaks. The cover, then gaskets, then cores followed by 2 more gaskets. You will probably destroy the gaskets getting it apart and need to make new ones. The cores are not supported in side. Silicone can be your friend when reassembling them. The Harrison cores are cupranickle and very rarely leak.
    Last edited by steveo143; 02-07-2013 at 11:14 PM.
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    Senior Member Hass828's Avatar
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    just plug the two outlets and then put a fitting witha schrader valve and a guage on the inlet , then pressure it up to 20psi and leave it alone for about 15-20minutes. If it holds then leave it alone and use it. If not then you'll need to disassemble to find the problem. Those last a long time.
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  8. #6
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    I have tested the Aero Marine intercooler using water for the pressure test and water came out of the intercooler air inlets. I feel certain this indicates a
    leak from at least one of the radiators.

    The radiators will be removed from the inter-cooling housing and taken to a radiator shop for repair. Is there anything in particular that I instruct them to do or check when repairing
    the radiators or should it just be a routine procedure for them.

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