Exhaust System: Testing and Inspection

Leak Test For Exhaust System

CAUTION: The maximum pressure permitted for performing the leak test is 1 bar.

NOTE: The leak test may not be carried out on a hot exhaust system, as the rubber seals are only functional at temperatures below 200 degrees C.

Tools







Item 1: Plug for exhaust system leak test










Clamping position: rubber seal constricted

Leak test







1. Remove tailpipes. To do this, unscrew the hexagon nuts of the fastening clamps, spread the clamps and completely remove tailpipe -tailpipe on the left in the Figure-.







2. Fit plug in exhaust pipe on the rear muffler. Insert the plug in the exhaust openings and twist the relevant lever clockwise or anti-clockwise to fit the diameter (rubber seals) until the exhaust openings are sealed airtight by repositioning the tensioning lever by 90 degrees.

NOTE: Do not exceed the permitted pressure of 1 bar.







3. Connect a pressure gauge to a valve and subject exhaust system to 1 bar of excess pressure.







4. Coat individual connectors on the exhaust system (e.g. manifold flanges, -see Figure-, clamping sleeves) with test spray in order to show up any leaks. Repeat test procedure if necessary.
5. Pull off pressure gauge, remove both plugs.

NOTE: Replace fastening clamps for tailpipes.







6. Fit tailpipes again. To do this, put the new fastening clamps (in the new installation position) -Figure shows right-hand side- with tailpipe onto the connecting pipe to the muffler. Slightly tighten the M8 hexagon nut with a commercially available long 3/8-inch socket wrench insert (a/f 16).
Installation position and tool for tailpipe fastening clamp (right-hand side)

7. Align tailpipes. To do this, position the tailpipes with respect to the rear spoiler.







8. Tighten hexagon nuts of the fastening clamps for the tailpipes to the specified torque.
Tightening torque for fastening nut (a/f 16): 30 Nm (22 ft.lb.)