Air Leaks, Air Intake and Exhaust Systems Page 1 of 8

010-024 Air Leaks, Air Intake and Exhaust Systems

Initial Check

Leaks in the intake air

system are most
commonly identified by:

1. Inspection of piping
for cracked or loose
clamps
2. Applying a solution of
soapy water in the
suspected area and
inspecting for
bubbles
3. Listening for high-
pitched whining or
sucking noise in the
suspected area.

CAUTION

Engine intake air must be

filtered to keep dirt and
debris from entering the
engine. If intake air piping
is damaged or loose,
unfiltered air will enter the
engine and cause
premature wear.

Inspect the inlet air piping

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for cracked hoses and

damaged or loose clamps.

Operate the engine at high

idle and use a solution of
soapy water to spot inlet
air leaks.

If an air leak exists at the

turbocharger fresh air inlet,
the soap bubbles will be
drawn in with the air.

Replace damaged pipes

and tighten loose clamps,
if necessary, to make sure
the air inlet system does
not leak.

Torque
Value: 10 n.m [89 in-lb]

Check for corrosion of the

inlet system piping under
the clamps and hoses.
Corrosion can allow
corrosive products and dirt
to enter the intake system.

Disassemble and clean as

required.

Pressure-Side Intake System

Leaks in the intake system

will reduce the amount of air
to the cylinders during engine
operation and decrease
engine performance.

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Operate the engine at full

throttle and rated rpm with
maximum load.

Listen for a high-pitched

whistling noise from the
turbocharger, nearby
piping, and connections.

Apply a soapy water

solution to sealing surfaces
and inspect for bubbles.

Leaks can also be found at

the turbocharger outlet
connection.

Inspect for damage,

replace sealing o-ring, and
tighten loose clamps.

Torque
Value: 10 n.m [89 in-lb]

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Charge Air Cooler Tubing

or Connection Hoses

Inspect the hose and

tubing for damage. Refer
to Procedure Procedure
010-019

Tighten loose clamps.

Refer to the equipment

manufacturer's
specifications for the
correct torque value.

Intake Manifold
Connection

Inspect for damage.

Tighten loose clamps.

Replace the connection

clamp, if necessary. Refer
to Procedure 010-023

Intake Manifold

Inspect for damage.

If damage is found,
replace the gasket if the
engine was originally
equipped with a gasket.

If the engine was originally

equipped with sealant,
replace with RTV sealant,
Cummins Part Number

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3164070 or equivalent.
Refer to Procedure
Procedure 010-023

Wastegate
Actuator/Plumbing

Inspect for damage. Refer

to Procedure Procedure
010-050

Compressor Housing
Sealing Surface

Inspect for damage.

Clean surface with a clean

cloth.

Exhaust System

Leaks in the exhaust system

will cause the turbocharger to
operate at a lower speed,
reducing the amount of air
going to the cylinders during
engine operation.

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Operate the engine at full

throttle and rated rpm with
maximum load.

Leaks can be identified by

noise, soapy water, or
discoloration caused by
the escaping hot gases.

Leaks can be found at:

l Exhaust manifold
gaskets

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l Turbocharger
mounting gaskets

l Turbine housing
sealing surface.

l EGR component
gaskets (if equipped).

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Last Modified: 07-Mar-2013

Copyright © 2000-2010 Cummins Inc. All rights reserved.

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