Diy Boost Leak Test

[xr_velocity]

I gathered some parts to get some boost leak testing happening today. I have a very loud whistle/whine sound on spool up which is not from faulty turbo bearings as I have replaced the turbo core recently. So all things point to a boost leak which I suspect is from around the turbo exhaust housing. But I wanted to make sure that the intake was not causing the problem.

1. I got out the air compressor, bought a Ryco 154 oil filter and drilled a hole in the top to which I screwed in an air compressor fitting along with an air tap and using some sikaflex stuck it in so it would be air tight. I hose clamped on a 3" silicone straight hose and then hose clamped that to the under battery intake. YOu don't have to use an oil filter, but it was the right size and all I could find.

2. I then unplugged the breather hose from the rocker cover, shoved a 3/8" socket extension up it and hose clamped it to get it air tight.

3. I bought a can of tuna, undid the inlet from the throttle body, put the tuna can in the silicone inlet and hose clamped it on...made sure to push the can right in there so the strong rim was being clamped down on...the rest of the tin will just crush.....an oil filter of the right size would have been better, approx 80mm...but I couldn't be bothered going back to Supers%^t Auto. In hindsight something more solid like an oil filter would have made a much better plug as I struggled to get a good seal with the tuna can...next time.

4. Turn on compressor, open up the tap on the home made inlet to your boost tester and let about 25-30 psi into the intake system.

5. Listen for a hissing noise...obviously this will be an air leak. Get some soapy water and a spray bottle and spray it on the entire intake....any leaks will start to bubble. You can see the bubbles in the pic below

Unfortunately this did not fix my problem, but it did uncover a couple of leaks which should not be there. Since turbo cars have a sealed, pressurised intake system, it should be checked occasionally for leaks. I found one leak in a faulty weld in my intercooler end tank and another in the fitting which screws into the under battery intake which connects to the rocker cover breather.

I fixed the breather hose with some teflon tape.

Edited 27/12/10 10:34 AM by xr_velocity

[xr_velocity]

The next step for me is to get a dump pipe flange for the turbo exhaust, get a plate welded onto it to make it airtight and the run my test again...except this time keeping the intake in the throttle body as the stop will be at the exhaust side of the turbo this time. This will let me test the intake and exhuast sides of the turbo, including intake and exhaust manifolds.

[Benny]

Great post and thanks for sharing. Got me thinking how I could test mine now.

Benny

[bjc]

that's a Rapids intercooler isn't it?

[xr_velocity]

that's a Rapids intercooler isn't it?

Yep.

[conrad]

Who makes the coolers from Rapids? Are they Aussie made?

[bjc]

Mate I have photos of his actual intake piping that I took before fitting to my car which still had the metal shavings from the bending inside them and the welding inside was like fcking stalagnites!

[hawlass]

Think the coolers are from an anonymous asian country,judging by the packaging writing.