Leak Testing Case Studies: Vauxhall V6 Inlet Manifold Leak Test Facility

Client: Tier 1 Automotive Engine Manufacturer

Part: V6 Engine Inlet Manifold

Machine supplied: Fully automatic combined leak test, pressure test and function test system

Overview: This system was designed and manufactured in order to give the customer the ability to 100% leak, pressure and function test V6 inlet manifolds within their production environment. TQC developed this system alongside the client to allow them to carry out a number of tests on their inlet manifolds.
Download details of this system as a PDF

The manifold leak test station consists of a test unit located in the V6 engine assembly area, and is a self contained, free standing unit consisting of an aluminium frame on which is mounted a loading fixture, an operator control closure, an electrical closure, a pneumatic air compressor and a hydraulic power pack.

The test component is manually loaded to a retractable drawer in the test machine, at which time an operator is required to connect the wiring harness to the connector provided and also connect the fuel rail connectors. At this point the drawer of the test machine is closed and the sealing begins.

The leak test instrument controls the complete leak test cycle, including fill, stabilisation and measurement, basic operating principle is that of measuring pressure decay in the test volume as compared with the pressure in a reference volume, both having stabilised to the same pressure before starting the measurement.

The facility is designed to carry out four automatic air decay tests on a manually loaded assembly. The main features and test performed are -

  • Air inlet branches
  • Fuel rail assembly
  • The opening value of the regulator fitted
  • Resistance test checking each type of injector
  • Pass label printing
  • Failed part label printing
  • Data logging / recording

Test pressures are controlled by an E-P regulator and are set to nominally 1.5 bar for the manifold, 4.0 bar for the fuel rail and 3.4 bar for the regulator.

Test parameters (time, alarm limits, etc) are programmable via the key pad on each instrument.

Results are indicated in terms of leakage rates (converted to cu.mm/sec) on each instrument when a positive leakage is measured.

This machine was one of a suite of 3 machines supplied to satisfy 3 engine variants.

To find out more about how we can help you with your leak testing requirements:

We build all machines in-house, applying our 25+ years experience in specialised test and automated handling machines experience to the engineering projects we undertake. We offer customer support, backup and service call-out for all projects, whatever the size.

Get in touch with us to discuss your requirements and we will be happy to offer our professional advice and visit you at your site.


TQC Ltd, Hooton Street, Carlton Road, Nottingham, NG3 2NJ, United Kingdom
Tel: +44 (0)115 9503561   |   Fax: +44 (0)115 9484642   |   E-mail: sales@tqc.co.ukSGS