Intake System/Leak Test

intake system/leak test

Special tools:
981 4215 Withdrawn replaced by 9512619 981 4215 Withdrawn Replaced By 9512619
999 5544 REGULATOR 999 5544 Regulator
999 5545 ADAPTOR 999 5545 Adapter

Preparations
- Check that all hoses are undamaged and are in place with their hose clamps tightened.

Note! In addition check the hose between the charge air cooler (CAC) and the idle air control (IAC) valve. Check for damage and cracking. Replace if necessary.

Tool, connecting




- Disconnect the fresh air intake hose from the mass air flow (MAF) sensor
- Connect special tool 999 5545 ADAPTOR 999 5545 Adapter and pressure regulator 999 5544 REGULATOR 999 5544 Regulator to the remove hose. Tighten the hose clamp
- Use a hose clip to seal the crankcase ventilation hose
- Remove the oil filler cap
- Disconnect the lower hose from the canister purge (CP) valve.

Checking the version




- Adjust the pressure regulator to a maximum pressure of 0.3 bar
- A gentle hissing sound may be heard from the oil filler opening. This is because an intake valve is open and cylinder pressure is leaking past the piston rings.
- Check the components and connections. See Checking air and vacuum hoses, turbocharged engines Checking Air And Vacuum Hoses, Turbocharged Engines
- Apply soap solution to the connections if leakage is suspected
- Bubbles are permitted around the throttle spindle
- Small bubbles are permitted between throttle body (TB) and the intake hose (if the hose is made of plastic). There must not be any bubbles if the hose is made of rubber
- Checking for air leakage from the canister purge (CP) valve. Leakage is not permitted.

Evaporative emission system (EVAP) valve, check

See Checking the canister purge (CP) valve Testing and Inspection.

Removing / installing:




- Remove tool 999 5545 ADAPTOR 999 5545 Adapter and pressure regulator 999 5544 REGULATOR 999 5544 Regulator from the fresh air intake hose
- Connect the hose to the evaporative emission system (EVAP) valve
- Connect the connector
- Connect the air intake hose.
Reinstall the valve, hoses, muffler and connector after the check is complete. Use clamp 981 4215 Withdrawn replaced by 9512619 981 4215 Withdrawn Replaced By 9512619 and a newhose clamp, P/N 97 81 65-9, when installing.