GROUP BUY Pressure test kit for S2/RS2/S4/S6

**bcdesigns** · 14 December 2004, 10:03

One for this table please!

**Pete_RS2** · 17 December 2004, 18:40

My test kit & IC mod arrived today. Cheers Lee

Does the IC hose need trimming or is it already cut to size ?

**Jamo** · 20 December 2004, 09:48

Lee you have pm, forgot about this as it's under the for sale section and not group buy. DOH!

Silly me.

**RS2.pt** · 20 December 2004, 12:46

Hi Lee
Am I in time to order one for me to? For an RS2.
I am from Portugal (LISBON).

Sorry not PM to you but I still cant figure where the heek is the PM button to reply to...

regards

Originally posted by Lee

Hi all,
These adapters are available in Europe for much more money so here is your chance to get one cheap. If 50 people are interested, the price somes down to Â£10.20+VAT delivered. Hard to beat I think. Outside the group buy they will be available for Â£15+VAT delivered so get one cheap now!

PLease state your interest by posting here or sending me a PM and I will update everyone on progress. I need to commit to these beofore 15 November to get this excellent price as there is workshop capacity available now.

Thanks for looking

Lee

**AndyP** · 9 January 2005, 13:06

Lee - You have PM

Andy

**bcdesigns** · 10 January 2005, 23:23

I tested the kit, the one that have the tyre valve, I connected it to the pipe of MAF, but the other? I tested on the Pipe, that connect to butterfly, and is too small for the hose!

Anyone help me? I have the AAN

**Doug_RS2** · 10 January 2005, 23:45

The other bung connects to the hose that comes from the IC to the metal pipe (before the throttle body).

**bcdesigns** · 11 January 2005, 09:56

But that bung is to small for my pipe diameter...

The one that connect the TB is this (the "y" form)

**Lee** · 11 January 2005, 20:52

The instructions are going to be posted tomorrow evening and I will provide a web-link. I have pictures and will indicate how to use the pressure test kit on 3B, ABY, AAN and ADU engines. I expect the instructions to be refined to include additional tests for the oil breather systems and special tests for cars running high boost.

Basic summary for now:
Insert pressure adapter into the hose that connects to the MAF. The other bung is used on 3B, ADU and ABY engines only. It goes in the hose that goes between the intercooler and the intake pipe. With this bung in place all hoses are tested with the exception of the one adjacent to the throttle body. If this bung is removed on these engines the cylinders are pressurised allowing all hoses to be tested. This bung is not used on AAN engines and when the pressure adapter is inserted, all hoses are pressurised.

Before pressurising the system a breather hose needs to be disconnected and plugged. This hose is the one that goes into the side of the camshaft cover of the engine. It is the breather hose that connects to the hose on the intake compressor side. To plug this you can use anything of the right size such as a 1/2â€ socket extension bar. I am in the process of getting an additional bung manufactured to do this job. When they are made I will ship them out Free of Charge to everyone that has bought a kit so far. This part, when made, will also be included in all future kits.

Now that all pressure test parts are in place you can start the test. You only need to pressurise this to a low pressure to check for leaks. If there is a leak, a low pressure will expose it. Cars running very high boost will need to modify this technique but I want to try it on a few cars first i.e. Doug and Tom. The best thing to pressurise the system is to use a regulated airline. Second choice is the tyre inflators used on petrol station forecourts (this is what I used). Home Tyre compressors generally cannot flow enough air to pressurise a system if you have a small leak so a better source of air is needed. Generally DIY tyre inflators use very small pistons to be able to pump to their rated pressures â€“ to something like 250bar on some models. Small pistons inevitably mean low flow rate. If you donâ€™t have an airline go to a petrol station, fit the kit in 5 minutes and inflate! I tested mine at just over 0.5bar gauge (with my thumb plugging the breather hole on the first one!!).

I am waiting for some photos from a few people that have the kits and these will feature in the instructions. The reason for the web-based instructions is that they can be continually updated to feature more cars and additional techniques for testing various elements. If there are queries they can be clarified for all by updating the webpage.

In the meantime, if there are any questions, please get in touch with me by email at lee@s2-parts.com

Many thanks

**bcdesigns** · 11 January 2005, 22:34

Ah, that explain the short bung

I tested the already, just the tyre valve bung, and i found one leak, rigth in the end of the hose (where the hose is conected to the turbo)...

rigth under my nose.... but there dont have preasure... i have to change it, and after run the other hoses

have to find a bung for "my" pipe...

**Lee** · 12 January 2005, 22:10

First version of the instructions have been posted. Please see www.s2-parts.com . I am awaiting some photos to expand on what is there and have been struggling to upload this site for a while now. Comments and feedback to the email address on the site I have linked to.

Many thanks, Lee

**Lee** · 12 January 2005, 22:14

Bruno, for now, just install the pressure adapter in place of the MAF. Leave the other bung out of the system. Plug the breather hose as shown in the S2 section on www.s2-parts.com, and pressurise. It is not mandatory to block the hose near the throttle body but it does allow one area to be eliminated from the test (piston ring blowby and IM vac hose connections).

**Lee** · 13 January 2005, 00:22

Web server for www.s2-parts.com is currently experiencing problems. I am checking it out.

**AndyP** · 14 January 2005, 20:08

OK so Iv'e passed stage 1, I actually removed the dump valve and the WGFV aswell so I could really isolate the source of the leak. All the pipes held the pressure no problem, in fact I think I may have used a little too much as the bung flew out and scared the cr*p out of me

Next stage was to reconnect the dump valve and try again. Now it wont build any pressure at all, the leaking air is coming back out past the throttle butterfly, i.e. out of the steel air intake pipe. I take it this means the DV is knackered? Anyway I'm going to try getting a new one tomorrow and will try again. Will let you know what happens.

Andy

**Lee** · 14 January 2005, 20:20

Surprised that the bung flew out...geez what pressure were you pumping it up to, or did you not tighten the hose clamp enough? There is a protrusion on the boduy of the bung and adapter to make sure it doesn't come out and I tested mine to well over 2 bar without issue. Any problems, drop me an email.

Just got some Piston-type Forge DVs (FMDV007P) in stock if you are interested. As always, competitive pricing for S2 Forum members.