Correct boost leak test procedure

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  • A80Avant
    S2Forum Obsessed
    • Sep 2005
    • 10873
    • Country: Greece

    #1

    Correct boost leak test procedure

    Hello all,
    i have bought a couple of test kits to perform a test on my car.However even before my project also now with the new setup i still cannot say i can perform the test properly.Either that or i am doing it right only i havent figured it out yet!
    Here is the thing:

    The bungs go:

    1)After MAF(hose maf to turbo compressor side)

    2)oil breather return

    3)Butterrly valve

    with a little customising the fitment in order to get the 3 parts on my new engine bay,i still get a hissing sound from the TURBO!!!! It seems that air passes through the middle part and dissipates slowly.Therefore i cannot pressurise the system since air continually is lost!!!

    My mechanic also told me that this should be bar for the turbo itself and suggested to pressurise AFTER the turbo.Only thing is that i dont have a bung with the slammer diameter of the exit of the turbo to the intercooler to bung.

    Fortunatelly i managed to resolve a small loss on the metal tube we built in one of the connections which needs a small welding but i cannot say that a 0.2mm hole can cause a boost drop of what im experiencing.We couldnt hear any hisses from the intercooler and the lower parts of the pressure side.Also the forge DV seems OK,no losses there.

    it should read: 1.75bar over boost 1.3bar steady
    it reads : 1.6bar over boost and 1bar steady


    your thoughts?

    cheers

    your thoughts??
  • S2central.net
    Retired OG Mod
    • Jul 2003
    • 16590
    • Country: Northern Ireland

    #2
    PapVas - I have posted about this in the past...

    You are correct - when you pressurise via the MAF hose you are presenting the turbo with somethingit never sees normally - pressure at the compressor inlet. This is normally under vacuum at all times. What is happening is that this compressed air during the test is leaking past the oil seal in your turbo. On my car (130k mile turbo) I can actually hear the bubbles getting into the sump.

    During this test all you are looking to do is certify the MAF hose is leak free.

    What I prefer to do, is pressure the system with specially made test bungs that I have for the compressor output hose - with that and a bung at the throttle body and a bung in the oil breather return (to MAF hose) then you can run a proper boost pressure test as that system of hoses should be airtight. Its a great way to test the intercooler and D'oh-ring...

    IIWU - get a test bung for the turbo output hose - its the only way to know for sure.

    Paul
    Paul Nugent
    Webmaster http://S2central.net
    Administrator http://S2forum.com

    1994 S2 Coupe ABY - aka Project Lazarus
    2001 A6 allroad 2.5TDi - family tank
    2003 S4 Avant 4.2 V8 - daily burble

    Purveyor of HomeFries and Exclusive agent for Samco hose kits (S2/RS2)

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    • A80Avant
      S2Forum Obsessed
      • Sep 2005
      • 10873
      • Country: Greece

      #3
      so what i have to do is build a bung for after the turbo,right?
      any suggestions where to find one???

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