It's common for charge air coolers leak, even new units. Most manufacturers have developed an "allowable leak rate" for their units.
Leaks will shorten the life of the engine, cause loss of engine power with the turbo chargers spinning at a higher RPM, and cause the piston cylinders to run hotter than they should. This shortens the life of the rings and valves and causes poor fuel economy.
At Dukane Radiator, we felt that the current charge air cooler designs on the market were unacceptable. Our unique bar and plate design far exceeds OEM standards, and can handle greater stresses than the traditional tube to header configuration. There are no tubes to crack or header joints to fail. Give our charge air coolers a try and see the difference.