Test Pressurization of the Charge Air Cooler and Pressure Pipes

Test Pressurization Of The Charge Air Cooler And Pressure Pipes, V6


To remove







1. Remove the engine cover.
2. Detach the turbo's bypass pipe from the intake pipe.


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


3. Remove the turbo pressure hose from the throttle body.
4. Remove the front exhaust manifold's heat shield.
5. Disengage the hose from the charge air cooler intake. Fit the plug, 83 94 595 Plug, turbo hose, into the hose.







6. Fit the plug, 83 95 436 Plug, turbo hose, V6, into the turbo pressure hose. Connect the pressure gauge equipment 83 93 514 Boost pressure gauge.
7. 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.


8. Connect a compressed air gun to the pressure gauge equipment, 83 93 514 Boost pressure gauge, and carefully build up a pressure of approximately 1 bar.
9. 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.
10. Check the hoses/pipe and compressed air gun for leaks using leak detection fluid part no.30 20 385 or similar.
11. If no leak is found in the hoses or pipes, carry out test pressurization on the removed charge air cooler.
12. Remove the charge air cooler.







13. Fit 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.
14. Connect a compressed air gun to the pressure gauge and carefully build up a pressure of about 1 bar.
15. Check that the pressure does not fall by mor 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







1. Attach the charge air cooler.
2. Connect the turbo pressure hose.
3. Fit the engine cover.
4. Fit the front exhaust manifold's heat shield.

Tightening torques:
Stud 22 Nm (16 lbf ft)
Locknut 24 Nm (17 lbf ft)

5. Fit the turbo bypass pipe.
Tightening torque: 8 Nm (6 lbf ft)


NOTE: Fit a new O-ring greased with non-acidic vaseline.