Intercooler: Testing and Inspection

To remove







1 Remove the bypass pipe.


NOTE: There is an O-ring where the bypass pipe is fastened to the turbocharger inlet pipe.


2 Remove the exhaust manifold heat shield. The heat shield is fastened with a nut and two clips underneath.
3 Detach the hose from the turbocharger outlet. Fit plug, part no. 83 94 595, into the hose.
4 Remove the engine cover.
5 Detach the air pipe from the throttle body.
6 Fit plug, part no. 83 95 030, into the turbocharger delivery pipe.







7 Connect pressure gauge equipment, part no. 83 93 514.
8 Connect pressure/vacuum pump, part no. 30 14 883, to the bypass valve. Pump up a pressure of approx. 1 bar.

IMPORTANT
Be extremely careful when pressurizing the turbo system. Excessive pressure may damage hoses and connections.

9 Connect an air gun, part no. 83 93 514, to the pressure gauge equipment and carefully build up a pressure of approx. 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 hoses/pipes and the air gun for leaks with fault tracing fluid, part no. 30 20 385, or equivalent.
12 If a leak is not detected in hoses or pipes, perform a pressure test on the dismantled charge air cooler.
13 Remove the charge air cooler.







14 Fit the inlet and outlet hoses to the charge air cooler and plug one of them. Connect pressure gauge equipment to the other hose.
15 Connect a compressed air gun to the pressure gauge and carefully build up a pressure of approx. 1 bar.
16 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. Use fault tracing fluid, part no. 30 20 385, or equivalent.

To fit


NOTE:
Fit new O-rings coated with acid-free petroleum jelly.
Spray the connector with kontakt 61, part no. 30 04 520.
Apply Molykote 1000, part no. 30 20 971, or equivalent to the studs.
Fit in reverse order.


Tightening torque's:
Bypass pipe/inlet pipe, bolt 8 Nm (5.9 lbf ft)
Bypass pipe, hose clip 8 Nm (5.9 lbf ft)
Look nuts, heat shield 20 Nm (14.7 lbf ft)