Testing For Leaks - Ford Rotunda Operation Manual

TESTING FOR LEAKS

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 Adaptor (see instructions) into intake ducting after air
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cleaner box. Begin a 10-minute vapor cycle and pressurize entire system with vapor at 5 PSI (0.35 BAR)
while inspecting for leaks using provided 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 Leak Testing
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 Adaptor (see instructions) into exhaust pipe. If
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using inside exhaust stack use the exhaust retention hoop to keep Power INTAKE Adaptor from falling
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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 Adaptor into a block off adaptor while injecting vapor into the system using the Temperature
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Sensor Port Adaptor, Pressure Sensor Port Adaptor or Oxygen Sensor Port Adaptor. These adaptors
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 Adaptor (see instructions) into intake ducting after air cleaner box AND
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install Power INTAKE Adaptor (see instructions) into exhaust pipe. Convert Power INTAKE Adaptor in
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exhaust system into a block off by installing block off coupler. Inject vapor into the intake system through
the Power INTAKE Adaptor. Pressurize entire system inspecting for leaks. Note: Complete system testing
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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.
Cabin 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 Smoke 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 adaptor 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.
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