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Test pressurising the charge air cooler and delivery pipes

Test pressurising the charge air cooler and delivery pipes

To remove

Important

Exercise great care when pressurising the charge air system. Too high pressure can damage the radiator, hoses and connections.



1. Remove the upper engine cover and insulation.

2. Detach the turbocharger delivery hose from the throttle body. Clean the hose with solvent before fitting the plug.


3. Fit EN-47656 Plug kit, turbo hose . Tighten the hose clip.

4. Detach the turbocharger delivery hose from the turbocharger.


5. Clean the hose with solvent. Fit EN-47656 Plug kit, turbo hose . Tighten the hose clip.

6. Connect 83 93 514 Boost pressure gauge to the plug.


7. Connect an air gun to the T-coupling of the boost pressure gauge.

8. Carefully create a pressure of around 1 bar.

Note

The pressure must not exceed 1.5 bar.


9. Check that the pressure does not fall more than 0.1 bar in 30 seconds. If the pressure drop is greater or if hissing can be heard, then check the hoses, pipes and connections for leaks. Use soap water or similar to detect any leaks.

10. If there are no leaks in the hoses or pipes and the pressure drops, remove the charge air cooler and test pressurise it. See to remove and to fit, charge air cooler .


To fit

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.



1. Release the pressure and remove the charge air pressure meter.

2. Remove the plugs from the charge air pipe hoses.

3. Attach the turbocharger delivery hose to the turbocharger.


4. Fit the turbocharger delivery hose to the throttle body.


5. Fit the insulation and upper engine cover.