Leak Testers for Intake and Intercooling Systems

Frequently Asked Questions About Pressure Testing and Leak Detection in Intake and Intercooler Systems

During a leak test, the intake or intercooler air path is deliberately sealed off and pressurized in a controlled manner. This allows pressure losses to be detected and leaky hoses, connections, or components to be systematically located. Here, we answer frequently asked questions about pressure testing and leak detection in intake and intercooler air systems.

• How is an intercooler system tested?

  A defined section of the charge air system is sealed at appropriate points using adapters or plugs.
  
  Pressure is then applied in a controlled manner via a filling adapter.
  
  The pressure gauge allows the test pressure to be monitored.
  
  If the system loses pressure, the cause or leak is then investigated.

• What test pressure is used when testing the intercooler system?

  There is no universally applicable test pressure for all vehicles.
  
  The permissible value depends on the specific intercooler system and the manufacturer’s specifications.
  
  Leitenberger MLPS systems feature a gauge with a range up to 2.5 bar and an overpressure protection device that limits the output to a maximum of 1 bar. However, this maximum value does not replace the vehicle-specific specification.

• Why do Leitenberg intercooler testers have a safety valve?

  The safety valve is designed to protect the test setup from excessive pressure.
  
  On the current MLPS 03, MLPS 04, and MLPS 06 models, the output is limited to a maximum of 1 bar.
  
  Regardless of this, testing must only be performed at a test pressure approved for the respective vehicle.

• What components can be tested using an intercooler test system?

  Depending on the vehicle and the selected test setup, areas such as:

  • intercooler hoses
  • intercooler pipes
  • connector fittings
  • gaskets
  • intercoolers
  • connections to the turbocharger
  • connections to the engine

  may be included in the test.

  The key factor is which points are sealed off for the test setup.

• How can you tell if there's a leak?

  A leak can, for example, be detected by a drop in pressure.
  
  Depending on the size of the leak and the test setup, escaping air or corresponding noises can also help pinpoint the leak.
  
  It is important to note that not every change in pressure automatically indicates a leak. Temperature changes and the specific test setup can also have an impact.

• Can an intercooler be tested using the tester?

  Yes, provided that the intercooler is integrated into the appropriately sealed test section and the test procedure is suitable for the vehicle.
  
  This also allows for the detection of leaks in the intercooler or at its connection points.

• Can gasoline and diesel engines be tested?

  The intercooler test is generally not limited to just one type of fuel.
  
  The key factor is that the vehicle has a turbocharged intake/intercooler system that can be tested, and that the adapters used and the test setup are appropriate.

• What is MLPS 03?

  MLPS 03 is a compact, four-piece intercooler test kit.
  
  It includes, among other things, a multi-stage adapter and plugs for 50, 60, and 70 mm diameters, as well as a filling adapter, pressure gauge, filling hose, and overpressure protection.

• What is the difference between MLPS 03 and MLPS 04?

  MLPS 04 offers a significantly wider range of diameters.

  The eight-piece set includes three multi-stage adapters and three sealing plugs each and, according to the current product description, covers diameters from 36 to 88 mm.

  MLPS 03, on the other hand, is the more compact version for 50, 60, and 70 mm.

• What is MLPS 06 intended for?

  MLPS 06 is specifically designed for vehicles in which the intercooler pipes are connected using click systems.

  The set includes six adapters and six plugs in the nominal diameters of 26, 32, 40, 45, 50, and 55 mm, as well as a filling adapter and a filling hose.

• What is the difference between MLPS 06 and MLPS 06_AK?

  MLPS 06 is the complete 14-piece set, including a filling adapter and filling hose.
  
  MLPS 06_AK, on the other hand, contains twelve adapters or plugs and is intended as a supplement when a filling adapter and filling hose are already available.
  
  This is particularly useful for workshops that already use MLPS 03 or MLPS 04.

• Why are there multi-stage adapters?

  Multi-stage adapters accommodate multiple hose or pipe diameters with a single component.
  
  This makes it possible to set up a universal workshop setup using relatively few individual parts.
  
  The MLPS 03 and MLPS 04 utilize exactly this principle.

• Why are there also special adapters for click systems?

  Quick-connect fittings have a different connection geometry than traditional hose connections.
  
  MLPS 06 therefore uses adapters and plugs specifically designed for this purpose.
  
  This allows the existing vehicle connection to be used for a defined test setup.

• What is the advantage of aluminum adapters?

  The current MLPS test kits use aluminum adapters or plugs.
  
  They are designed for repeated professional use in workshops and ensure a stable test setup.

• Can the intercooler system be inspected even after a repair?

  Yes.

  After working on, for example:

  • intercooler hoses
  • intercoolers
  • turbochargers
  • connectors
  • gaskets

  it may be advisable to perform a leak test to check the repaired section of the system before the final functional test.

• Can you use the tester to measure boost pressure while driving?

  The MLPS/LPS systems in this subcategory are primarily intended for leak testing and leak detection on a shut-down or appropriately prepared intercooler system.

  Turbocharger test and diagnostic tools are available for actual boost pressure measurement and further diagnostics.

• Is an intercooler leak test the same as a turbocharger diagnostic test?

  No.

  The leak test primarily answers the question:

  Is the tested air path sufficiently airtight?

  As part of a comprehensive turbocharger diagnosis, the following can also be examined, for example:

  • Boost pressure
  • Control pressure
  • Pneumatic control
  • Exhaust back pressure
  • Crankcase pressure.

  The turbocharger test and diagnostic equipment is available for this purpose.

• Why might it also be useful to measure crankcase pressure?

  A problem such as oil in the intake tract is not necessarily caused solely by the turbocharger.

  The crankcase ventilation system or unusual crankcase pressure may also play a role.

  Crankcase pressure gauges for blow-by gases are available for this purpose.

• What equipment is recommended for a systematic intercooler diagnosis?

  Depending on the type of fault, the following may also be required:

  • Leak testers for intake and charge air systems
  • Test and diagnostic equipment for turbochargers
  • Crankcase pressure gauges for blow-by gases
  • Electronic vehicle diagnostics
  • Exhaust pressure testing, if necessary

  You can find additional solutions under Test Equipment for Fresh Air, Intake, and Charge Air Systems.