Test pressurising the charge air cooler and delivery pipes
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Test pressurising the charge air cooler and delivery pipes
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Important
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Exercise great care when pressurising the charge air system. Too high pressure can damage the radiator, hoses and connections.
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1.
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Remove the battery cover, the radiator pipe and engine cover.
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2.
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Attach the battery cables and fit the battery.
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3.
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Undo the main fuse box in front of the battery tray and move it aside.
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4.
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Detach the fuse holder from the battery tray.
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5.
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Remove the cable duct from the battery tray.
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6.
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Unplug the bonnet switch connector, detach the cable clip and remove the battery tray.
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8.
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Unplug the boost pressure sensor connector (688).
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9.
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Detach the upper charge air pipe from the throttle body and detach the lower pipe.
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12.
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Connect an air gun to the charge pressure meter's T-coupling.
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13.
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Carefully create a pressure of around 1 bar.
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14.
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Check that the pressure does not fall more than 0.1 bar in 30 seconds. If the pressure drop is greater or if hissing can be heard, then check the hoses, pipes and connections for leaks. Use soap water or similar to detect any leaks.
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15.
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If there are no leaks in the hoses or pipes and the pressure drops, remove the charge air cooler and pressure test it. See To remove and to fit, charge air cooler.
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1.
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Release the pressure and remove the charge air pressure meter.
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Important
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To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
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2.
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Remove the plugs from the charge air pipe hoses.
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3.
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Attach the upper charge air pipe to the throttle body and attach the lower pipe.
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Important
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Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to
Connectors, handling and inspection
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4.
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Plug in the boost pressure sensor connector (688).
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5.
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Attach the turbocharger delivery hose to the turbocharger.
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6.
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Plug in the bonnet switch connector, fit the cable clip and install the battery tray.
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7.
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Fit the cable duct on the battery tray.
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8.
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Fit the fuse holder on the battery tray.
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9.
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Install the main fuse box in front of the battery tray.
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10.
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Fit the battery and attach the cables.
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11.
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Fit the engine cover, radiator pipe and battery cover.
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