INSTRUCTIONS FOR ALL UNIVERSAL BOOST LEAK TESTERS
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We really hope that you are satisfied with your boost leak tester purchase and always willing to support with product or technical information and will work with you on any issues with your order.
With this boost leak tester you’ll be able to pressurize and listen for leaks with the engine off by using an air to simulate the same conditions as the turbo if it was spinning and making boost. Installing the tester kit on either the turbo inlet or other convenient test locations will allow you to pressurize the charge air path “intake” with an air compressor and test every single connection that usually sees boost pressure, including clamped connections, faulty intercoolers, bov or bypass valve diaphragms, throttle body, weld joint cracks, injector seals, check valves, old & cracked hoses, vacuum lines, gasket and seal surfaces, plus many more. A motor with boost leaks can cause a loss of fuel economy, check engine lights, increased intake temps, knocking, and offset air fuel ratios. Depending on the size of the leak, overspinning the turbo because of the leak can overwork the bearings causing shaft play and ultimately turbo failure. Large leaks are more obvious because of air whistling and a large loss of power and usually get fixed quickly. However, the smaller leaks are the silent killers of turbo bearings as they go undetected by the driver and will destroy a turbo over time. Once the bearings are compromised, this is known as shaft play, the compressor or turbine wheel become imbalanced and start to contact the housing and get chewed up.. Inevitable turbo replacement and possible engine damage are a result at this point of failure. Best is to catch leaks before the turbo develops shaft play.
ASSEMBLY
Your boost leak tester comes partially assembled. When connecting the silicone hose to the end cap, slide the silicone up to the top edge of the end cap and then tighten the clamp down onto the end cap. See image to the right.
Rotating the Boost Gauge for better visibility- Do not rotate or adjust the gauge by hand, it will damage the gauge. Use a 7/16” or 11mm wrench at the base of the gauge to rotate.
T-bolt Clamps - Do not over tighten the clamp as this could cause the clamp to fail and cause a dangerous situation where the tester can pop off. If you do not feel comfortable working with compressed air and pressurized components please visit a shop or consult a professional.
HOW TO USE THIS BOOST LEAK TESTER:
1 - Remove intake from turbo charger inlet (in some cases the turbo is difficult to access and you will test before the turbo)
2 - Secure the boost leak tester to the turbo or other location of choice. *Use safety goggles and face protection and always stand clear from the tester in case it pops off under pressure
TIP: Always remove the oil cap to vent any built up pressure in the crank case system when pressurizing. This relieves the pressure off the cam/crank oil seals in case there is an internal boost leak leaking into the crank case (usually through a bad check valve).
3 - Set your air compressor to a low pressure (about 20 PSI to start) and attach your line to the boost leak tester and start to fill the system. Increase compressor pressure as needed to achieve about 5 PSI in the intake piping.
TIP: If you are finding it is difficult to fill the system, or not building pressure, increase the compressor pressure as needed. If there is a large difference between the compressor outlet and the pressure on the boost leak tester then this indicates pressure is being lost inside the motor (if there are no audible leaks). A bad check valve or egr valve stuck open, for example, can be the cause.
4 - Watch the gauge on the boost leak tester rise until you reach about 5 PSI.
5 - Listen for leaks. A boost leak will be obvious and sounds like air rushing out. Fix any leaks and re-pressurize the system (increase the compressor if necessary) to see 10 PSI on the boost gauge to catch the next obvious leak point. Use soapy spray to catch smaller leaks by evidence of bubbles forming.
6 - Repeat steps 4 & 5 and work up to 15 PSI and 20 PSI. Most leaks are found with less than 20 PSI of pressure
7 - Pro Tip: After fixing all leaks, fill the system one last time and remove the air compressor line and let the intake system naturally bleed down and evaluate the rate of the pressure drop. This is another good way to evaluate the intake system’s ability to hold boost. It is normal for an engine to lose pressure about 1 PSI/second (at 20 psi) and will slow down at lower pressures, losing 1 psi every few seconds. This is general and some engines will lose more, some less. Keep in mind that pressure will pass into the engine, into the cylinders, past the rings and into the crank case system, so a natural pressure loss is normal. This is why it is important to vent the crank case by removing the oil cap during testing. Especially in the case a PCV check valve is bleeding air into the crank case, it is ideal to have that air vented.
Troubleshooting ***PLEASE READ***
“My Gauge Reads 0 PSI - The Boost Leak Tester is not working!”
The gauge is actually working properly and doing its job. Pressure is not building in the charge pipes and its reading 0 PSI as a result.
Recommendations:
- Turn up your air compressor, you may be at too low of a compressor pressure not building pressure faster than it is lost through the leak point.
- Check that all lines are connected, relief/bov valves, vacc lines, etc.
- A faulty check valve between the boost/manifold and the pcv system will leak all air into the pcv and not build pressure during the test.
If these recommendations dont work, contact us and we will be happy to assist.
“The gauge is stuck at a pressure above 0 PSI”
Once in a while during manufacturing, there is a built up pressure inside the gauge’s stainless housing that holds in the glycerin oil. To relieve this pressure, at the top of the gauge there is a rubber grommet, nudge or pinch it to release the air and the gauge will reset back to 0 PSI.
*Be careful to do this with the gauge upright so no fluid spills and creates a mess. The fluid is inert and not harmful. It is used as a shock absorber for the needle. The gauge will work perfectly with or without the glycerin oil.
SAFETY
Always use safety protection when using compressed air to protect your face, body and anything in the direct line of fire of the boost leak tester. If not secured well, the boost leak tester may pop off under pressure causing harm. Stand clear from the direction the tester is installed
RETURNS
We strive to improve the products we have and if you do have a return we ask you let us know why so we can improve the product for future customers. If you have a return, reach out and we will process it asap. If you have simply ordered the incorrect size give us a call we can most likely work with the kit that you have already and offer deep discounts on an adapter size that will work for you.
Legal Disclaimer
TURBO BOOST LEAK TESTERS, INC., AND/OR ANY OF ITS DIRECTORS, EMPLOYEES, AND AFFILIATES ARE NOT RESPONSIBLE FOR ANY INJURY, DEATH OR PROPERTY DAMAGE ASSOCIATED WITH THE PURCHASE AND USE OF ANY PRODUCT(S) PURCHASED FROM TURBO BOOST LEAK TESTERS, INC. THE PURCHASER, ASSUMES SOLELY THE RESPONSIBILITY OF ENSURING THAT ALL SAFETY PRECAUTIONS, RESTRICTIONS AND WARNINGS ARE ADHERED TO. MOREOVER, IT IS THE RESPONSIBILITY OF THE PURCHASER TO ABIDE BY ALL STATE, LOCAL AND FEDERAL LAWS WHEN USING ANY PRODUCT(S) PURCHASED FROM TURBO BOOST LEAK TESTERS, INC. THE PURCHASER AGREES TO INDEFINITELY AVOID ANY MISUSE OF THE PRODUCT AND TURBO BOOST LEAK TESTERS, INC. WILL BE NOT BE HELD LIABLE FOR INDIRECT, INCIDENTAL, AND/OR CONSEQUENTIAL DAMAGES CAUSED BY THE PURCHASE, INSTALLATION, AND/OR USE OF THE PRODUCT. YOUR PURCHASE FROM TURBO BOOST LEAK TESTERS, INC. IS YOUR UNDERSTANDING AND ACCEPTANCE OF THE ABOVE DISCLAIMER. SAFETY WARNING WHEN USING COMPRESSED AIR, OBJECTS MAY EXPLODE AND ACT AS PROJECTILES THAT MAY CAUSE SERIOUS PERSONAL INJURY OR DAMAGE. THEREFORE, FOR YOUR OWN SAFETY, WHEN USING COMPRESSED AIR ALWAYS WEAR APPROVED ANSI (AMERICAN NATIONAL STANDARDS INSTITUTE) SAFETY GLASSES OR GOGGLES. MOREOVER: WHEN PRESSURIZING THE BOOST LEAK TESTER ALWAYS STAY CLEAR OUT OF THE LINE OF FIRE. BE AWARE OF OTHER COMPONENTS ON THE ENGINE THAT WILL BE PRESSURIZED DURING THE BOOST LEAK TEST. THESE OTHER COMPONENT MAY ALSO EXPLODE AND ACT AS PROJECTILES. TO PREVENT ENGINE DAMAGE ALWAYS SET YOUR AIR COMPRESSOR TO A LOW OUTLET PRESSURE SETTING TO AVOID ACCIDENTAL OVERCHARGING. DO NOT EXCEED THE NORMAL BOOST LEVEL THE VEHICLE IS CALIBRATED TO. ALWAYS REMOVE THE OIL CAP TO VENT EXCESS PRESSURE IN THE CRANKCASE. THIS PREVENTS POTENTIAL ENGINE OIL SEAL DAMAGE. PLEASE AVOID ANY MISUSE OF THE PRODUCT AND ADHERE TO ALL SAFETY PRECAUTIONS AND WARNINGS WHEN USING THIS PRODUCT.