Test Pressurization of the Charge Air Cooler and Pressure Pipes

Test Pressurization Of The Charge Air Cooler And Pressure Pipes, 4-cyl.

To remove







1. Remove the bypass pipe.


NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.


2. Remove the exhaust manifold heat shield. The heat shield is attached with a nut and two clips on the underside.
3. Disengage the hose from the charge air cooler outlet. Fit the plug, 83 94 595 Plug, turbo hose, into the hose.
4. Remove the engine cover.
5. Detach the air pipe from the throttle body. Remove the hose elbow.







6. Fit a section of hose with an inside diameter of 50 mm and a length of 50 mm on the pipe.
7. Fit the plug, 83 95 030 into the turbocharger delivery pipe. Connect the pressure gauge equipment, 83 93 514 Boost pressure gauge.
8. Connect the pressure/vacuum pump, 30 14 883 Pressure/vacuum pump, to the charge air bypass valve. Build up a pressure of approximately 1 bar.


IMPORTANT:
Be extremely careful when pressurizing the turbo system. Too high a pressure may damage hoses and connections.


9. Connect a compressed air gun, 83 93 514 Boost pressure gauge, to the pressure gauge equipment and carefully build up a pressure of about 1 bar.
10. Make sure that the pressure does not drop by more than 0.1 bar in 30 seconds. If the pressure drop is greater than this or if there is an audible hissing sound, check hoses, pipes and connections for leaks.
11. Check the hoses/pipe and compressed air gun for leaks using leak detection fluid, part No.30 20 385 or similar.







12. If no leak is found in the hoses or pipes, carry out test pressurization on the removed charge air cooler.
13. Remove the charge air cooler.
14. Fir the inlet and outlet hoses on the charge air cooler and plug one of the hoses. Connect the pressure measuring equipment to the other hose.
15. Connect a compressed air gun to the pressure gauge and carefully build up a pressure of about 1 bar.
16. Check that the pressure does not fall by more than 0.1 bar in 30 seconds. If the pressure drop is greater than this or a hissing sound is heard, check the hoses, pipes and connections for leaks. Use leak detection fluid, part No.30 20 385, or similar.

To fit


NOTE:
Fit new O-rings greased with non-acidic vaseline.
Spray the connectors with Kontakt 61 contact cleaner, part No.30 04 520.
Coat the studs with Molycote 1000, part no.30 20 971, or similar.

Fit in reverse order.

Tightening torques:
Bypass pipe/intake pipe, bolt 8 Nm (6 lbf ft)
Bypass pipe, hose clip 8 Nm (6 lbf ft)
Locknut, heat shield 20 Nm (15 lbf ft)