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Which side are you blowing the intercooler lines off? Hot or cold side?
Have you tested the intercooler for blockages? What about the tubes, do they look bent at all? There has been issues with them being bent allowing pressure loss on the system and the lines to blow off.
There is a TSB for it, too.
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.
Oil seepage from turbo charge air cooler hoses, or charge air cooler hose becomes dislodged during acceleration.
It is possible to have DTC P0299.
Due to the closed PCV system on the 6.6 LLY engine it is normal to have oil residue in the air charge cooler hoses and pipes.
The oil will migrate to the lower areas of the air charge cooler system and may cause customer concerns of oil seepage.
This may also cause the Charge Air Cooler hoses to dislodge when turbo boost is high.
Do a visual inspection of Charge Air Cooler connections and hoses.
Replace Charge Air Cooler hoses, pipes, or clamps if damaged.
Properly clean all oil from Charge Air Cooler pipes and hoses.
Charge Air Cooler hoses and pipes are marked for proper installation. The hoses are marked with ENG, DUCT, or CAC (charge air cooler). The hoses and pipes must installed correctly. The engine side is marked ENG, the duct side (the aluminum pipe) is marked DUCT, and the charge air cooler side is marked CAC.
Apply a very thin coat of sealer part number 97720043 to the Charge Air Cooler hose connections.
Install hose and properly torque charge air coolerhose clamps to 70 lb in/8 nm.
Allow the RTV sealer to dry for 3 to 4 hours. Recheck the Charge Air Cooler for leaks using the appropriate Kent Moore leak tester.
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