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Pressure testing the charge air cooler and delivery pipe

Pressure testing the charge air cooler and delivery pipe

To remove

Important

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



1. Raise the car.

2. Remove the lower engine cover.

3. Detach the turbocharger delivery hose from the turbocharger.


4. Clean the hose with solvent. Fit 83 94 587 Plug, turbo hose . Tighten the hose clip.

5. Lower the car to the floor.

6. Remove the upper engine cover and insulation.

7. Remove the turbo pressure hose from the throttle body. Clean the hose with solvent before fitting the plug.


8. Fit 83 95 030 Plug, turbo hose . Increase the diameter of the plug by winding a few turns of plastic tape around the plug. Tighten the hose clip.

9. Connect 83 93 514 Charge pressure meter to the plug.


10. Connect a compressed air gun to the charge pressure meter's T-coupling.

11. Carefully create an overpressure of about 1 bar.

Note

The pressure must not exceed 1.5 bar.


12. Check that the pressure does not drop by more than 0.1 bar over 30 seconds. With a large pressure drop, or audible hissing sound, check the hoses, pipes and connections for leakage. Use soapy water or similar to detect any leakage.

13. If no leakage is detected on hoses and pipes in the event of pressure drop, pressure test the removed charge air cooler. See: To remove, 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 overpressure and remove the charge pressure meter.

2. Remove the plugs from the charge air pipes' hoses.

3. Fit the turbo pressure hose to the throttle body.


4. Fit the insulation and the upper engine cover.

5. Raise the car.

6. Remove the plug for the charge air pipe's hose.

7. Fit the turbo pressure hose onto the turbo.


8. Fit the lower engine cover.

9. Lower the car to the floor.