Test Pressurization of the Charge Air Cooler and Pressure Pipes

Test pressurization of the charge air cooler and delivery pipes






To Remove

1 Remove the bypass pipe, 1 bolt on the turbo intake pipe and 1 hose clip.

NOTE: There is an O-ring at the bypass pipe mounting on the compressor inlet.

2 Remove the exhaust manifold heat shield. The heat shield is attached with a nut and two clips on the underside.
3 Detach the hose from the turbocharger outlet to the charge air cooler. Fit a plug, tool no.83 94 595, in the hose.
4 Remove the engine cover.
5 Detach the turbocharger delivery pipe from the throttle body (2 hose clips). 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, tool no. 83 95 030, in the turbocharger delivery pipe. Connect the pressure gauge, tool no. 83 93 514.
8 Connect pressure/vacuum pump 30 14 883 to the bypass valve. Pump up a pressure of approx. 1.0 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 to the pressure gauge, tool no. 83 93 514, and carefully create 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 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 Fit the inlet and outlet hoses to the charge air cooler and plug one hose.
15 Connect a compressed air gun to the pressure gauge and carefully create 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, part no. 30 04 520.
Coat the studs with Molykote 1000, part no. 30 20 271 or similar.

Fit in reverse order.
Tightening torque: bypass pipe 8 Nm (5.9 lbf ft)