BTS MESS02 User manual

Operating instructions
Turbocharger Diagnostic Tool MESS02, operating instructions MESS02 Seite 1von 9
en
Turbocharger Diagnostic Tool MESS02

Operating instructions
Turbocharger Diagnostic Tool MESS02, operating instructions MESS02 Seite 2von 9
en
Described product Turbocharger Diagnostic-Tool
Manufacturer
BTS Turbo GmbH, Paradeisstr. 56, 82362 Weilheim, Germany
Legal information
This work is prodected by copyright . The rights established thereby remain with the company BTS Turbo GmbH. Reproduction of this work or parts of this work is
only permitted within the limits of the statutory provisions of copyright law. Any modification, shortening or translation of this work without the explicit written
consent of the BTS GmbH is prohibited. We reserve the right to make product changes in terms of appearance, dimensions, weight, functional status, properties
and performance in the course of improvement and adaption to the state of the art. This does not entail any entitlement to correction or subsequent delivery of
products that have already been delivered. Cancellations can be made at any time without creating a legal claim. All instructions for use and safety are non-
binding. In no case do they replace any legal or trade association regulations. Trademarks mentioned in this document are the property of their respective owners
© BTS Turbo GmbH. All rights reserved.
This document is an original document of BTS Turbo GmbH.
Table of contents
1. Safety ............................................................................................................................................................................................................2
1.1 General safety instructions and regulations.............................................................................................................................................2
1.2 Instructions for use ....................................................................................................................................................................................2
1.3 Intended use ...............................................................................................................................................................................................3
1.4 Disclaimer ...................................................................................................................................................................................................3
1.5 Environmental conditions..........................................................................................................................................................................3
2. Product description......................................................................................................................................................................................3
2.1 Tool view.....................................................................................................................................................................................................3
2.2 Scope of delivery........................................................................................................................................................................................4
2.3 Adapter list..................................................................................................................................................................................................4
3. Application examples...................................................................................................................................................................................5
3.1 Application example: Checking the crankcase internal pressure...........................................................................................................5
3.2 Application example: Checking exhaust back pressure..........................................................................................................................6
3.3 Application example: Checking the control pressure on the pneumatic control box............................................................................6
4. Product description (pressure gauge) ........................................................................................................................................................7
4.1 Device view, buttons and functions ..........................................................................................................................................................7
4.2 Installation / inserting / changing the battery ...........................................................................................................................................7
4.3 Calibration...................................................................................................................................................................................................8
5. Care and storage ..........................................................................................................................................................................................8
6. Environmentally friendly disposal...............................................................................................................................................................8
7.Technical data, specifications (pressure gauge).........................................................................................................................................8
8. Operating instructions (pressure gauge)....................................................................................................................................................8
1. Safety
1.1. General Safety instructions and regulations
In order to be able to guarantee safe and reliable work with the Turbocharger Diagnostic Tool and to protect the user from
injuries, the following points must be observed:
Please read the user manual carefully.
The Turbocharger Diagnostic-Tool may only be operated by trained specialists and may only be used on vehicles with
combustion engines. The user must have the appropriate specialist knowledge and qualifications for the area of application, be
familiar with the applicable standards, regulations and specifications and observe them.
The operating instructions are part of the diagnostic tool. Keep the manual in a safe place so that you can quickly find the required
information you need when needed.
In general, the legal specifications and regulations as well as the specifications and regulations of the vehicle manufacturer must
be observed.
1.2. Instructions for use
Before each use, ensure that the Turbocharger Diagnostic-Tool and all it´s components are in perfect condition. For all work on
the vehicle, only the data specified by the vehicle manufacturer apply. All listed vehicle-specific data are subject to change.
Only use original spare parts and accessories.
Using the product beyond the specification or disregarding the safety and operating instructions can lead to serious malfunctions
as well as personal injury and damage to property.
Wear personal protective equipment when working with the Turbocharger Diagnostic Tool.

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1.3. Intended use
The Turbocharger Diagnostic Tool is used to test various pressures, such as the crankcase internal pressure and the
exhaust back pressure as well as to test the pneumatic boost pressure control on combustion engines.
Warning
Danger from improper use
Any improper use and disregard of safety and operating instructions can lead to serious malfunctions as well as personal
injury and damage to property.
- Only use the Turbocharger Diagnostic Tool in accordance with the intended use.
- All information in the operating instructions must be strictly observed.
1.4. Disclaimer
If the intended use is not observed, all guarantee and warranty claims against the manufacturer will immediately expire.
No liability is accepted for damage or malfunctions caused by improper use, assembly errors or non-compliance with the operating
instructions.
1.5. Environmental conditions
The Turbocharger Diagnostic Tool is only to be used in a commercial workshop area.
2. Product description
The Turbocharger Diagnostic Tool enables a quick and easy mechanical diagnosis of the turbocharger environment without an
OBD diagnostic tester. The three proven rapid tests provide a quick overview when checking the the crankcase pressure,
the exhaust back pressure and the pneumatic boost pressure control.
2.1 Tool view
2.2 Scope of delivery
Pos.
Description
Pos.
Description
1
Pressure gauge with DN5 plug nipple
8
Hose connection adapter
2
Adapter EFTA15
9
T- piece 6/6/6
3
Adapter EFTA13
10
T- piece 4/6/4
4
Adapter EFTA09
11
Hose 2,5 m with plug-in connector (2 pieces)
5
Adapter EFTA08
12
Hose 25cm (2 pieces)
6
Adapter EFTA17
13
Foam insert (milled)
7
Adapter EFTA01
14
Plastic case

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2.3 Adapter list
Description
Use
Connector
Item no.
Image
EFTA 01
Audi, BMW, Porsche, Mercedes-Benz, Toyota, VW,
Seat, Skoda, u.a.
Replacement seal: ET 960, item no.120460_1
Bayonet closure
040604
EFTA 08
Opel/GM Org.Tl.Nr. 90412508, 55566555
Replacement seal: ET 1046, item no. 120494_1
Bayonet closure
040615
EFTA 09
VW-Konzern ab Einführung MQB-Plattform, Golf VII u.ä.
Replacement seal: ET 962, item no. 120462_1
Bayonet closure
040613_1
EFTA 13
Mercedes Citan W 415, OM 607,
Renault Kangoo ab 2013, K9K-Motor
Replacement seal: ET 1047, item no. 120495_1
Bayonet closure
040625_1
EFTA 15
Mercedes M 282 Otto 1.4l
Org.Tl.Nr. A 282 018 11 00
Mercedes OM 654 Diesel
Org.Tl.Nr. A 654 010 26 02
Replacement seal: ET 964, item no. 120464_1
Bayonet closure
040627_1
EFTA 17
VW-Motor EA211evo
Replacement seal: ET 1049, item no. 120497_1
plugged
040632_1
3. Application examples:
3.1 Application example: Checking the crankcase internal pressure
Term definition:
Crankcase ventilation = CV
To check the crankcase internal pressure, use the vehicle specific adapter for the valve cover or oil filler neck. Plug the configured hose
into the mounted adapter and connect it to the electronic manometer.
Unfortunately, we do not have any reliable manufacturer information from the vehicle manufacturers regarding the crankcase internal
pressure. The following values are empirical values from many differentiated tests. In general, the statement applies that the crankcase
internal pressure should generally be negative, upward deviations should not exceed +5 mbar, underpressures greater than -90 mbar
are alarming for the motor from a technical point of view.
Vehicle specific adapter

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Turbocharged diesel vehicles:
Checking the CV at idle speed:
• The measured pressure must not exceed + 5 mbar.
A negative pressure of up to –10 mbar is permitted.
Checking the CV at 3500 rpm (stationary):
• The value measured when idling must not increase upwards, as a general rule, a positive value goes into the vacuum range.
A negative pressure of max. -20 mbar is considered normal.
Checking the CV while driving at all speeds and for performance:
• Depending on the speed and performance requirement, the measured values are between –40 mbar and 0.
Brief overshoots of up to +10 mbar are to be considered tolerable.
Gasoline vehicles (Otto engines) with turbocharger:
Checking the CV at idle speed:
• Depending on the manufacturer, the values are between -90 mbar and -15 mbar.
Checking the CV at 3500 rpm (stationary):
• With negative intake manifold pressure (induction operation), the values usually remain in a clearly negative range.
Checking the CV while driving at all speeds and for performance:
• If the intake manifold pressure is positive (loading operation), the CV switch to a different operating state.
From now on, the internal pressure will range between -45 mbar and 0.
Brief overshoots of up to +10 mbar are to be considered tolerable.
• The idle speed values apply in coasting mode.
Turbocharged gas vehicles:
Are comparable to Otto engines
Note:
A faulty crankcase ventilation is responsible for compressor-side and/or turbine-side oil losses in turbochargers. Accumulations of oil in
the boost pressure line can have devastating effects when driving. In the case of turbochargers with variable turbine geometry, oil loss
on the exhaust side causes errors in the boost pressure control and permanent damage to the components of the exhaust gas cleaning
system.
With this tool and the extensive range of adapters, functional faults in the crankcase ventilation can be determined. This rules out
consequential damage or repeated failures of the newly installed turbocharger.
3.2 Application example: Checking exhaust back pressure
Term definition:
Exhaust back pressure = exhaust pressure between the turbine outlet of the turbocharger and the first component in the exhaust system
Differential pressure sensor = electronic Sensor that determines the differential pressure between DPF inlet and outlet or DPF inlet and
atmosphere.
The electronic pressure gauge must be used with the pre-assembled hose.
Connect to the front test line of the DPF using the appropriate T-piece and connecting hose.

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Checks of the exhaust back pressure must always be carried out while driving for speed and power.
It is advisable to take into account the kilometers driven since the last successful regeneration of the DPF.
The upper limit of acceptable exhaust back pressure is +300 mbar
In vehicles with an SCR catalytic converter after the DPF, it is advisable to also check the exhaust back pressure after the DPF.
Here the measured value should not be above +100 mbar.
Checking the back pressure after the DPF is also recommended for vehicles with low-pressure EGR.
For active EGR in the partial load range, the manufacturer's information should be used.
When the dynamic pressure flap is open in the full load range, the exhaust back pressure after the DPF should be less than 70 mbar.
Note: The first approach is to measure the back pressure in front of the diesel particulate filter.
In vehicles with a downstream SCR catalytic converter with AdBlue injection,
a check behind the DPF is very useful as it usually shows quite sobering results.
An SCR catalytic converter and the muffler must not generate any back pressure.
Vehicles with low-pressure EGR are usually equipped with a controlled dynamic pressure flap in the exhaust pipe after the DPF.
If there is an undetected malfunction, this also leads to incorrect measurement results from the built-in differential pressure sensor.
In the case of a petrol engine, one does not generally expect an increased exhaust back pressure.
However, from our experience at BTS, this has turned out to be a misconception.
Damaged 3-way catalytic converters are not uncommon.
Inadequate control times due to chain elongation and defective injectors are usually the culprits.
In the future, the Otto particle filter will, in some cases, also make itself known as a recurring cause of problems in turbochargers.
With our tool, the exhaust gas pressures can also be measured here.
3.3. Application example: Checking the control pressure on the pneumatic control box
The electronic pressure gauge must be used with
the pre-assembled hose.
Connect to the vacuum line between the boost pressure control valve and the turbocharger control box using the appropriate T-piece
and connecting hose.
The electronic pressure gauge of our measuring tool is used to test all pneumatic actuators on the turbochargers. The pressures can
also be determined while driving on pressure and vacuum-controlled actuators. A comparison of the determined pressures with the cycle
rates of the electropneumatic converters can thus be implemented.
Measurement data from pressure sensors such as the boost pressure sensor or the differential pressure sensor can be checked very
precisely.
Leaks in the vacuum system or a lack of wear on the vacuum pumps can be determined with an appropriate test routine. To do this, the
vacuum present at the actuator is determined at idle speed. If the foot brake is actuated several times, the determined value must not
drop. If there are no leaks in the assemblies involved in the vacuum, then a defect in the vacuum pump will be found.

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4. Product description (pressure gauge):
The DM 80_L is a digital pressure gauge with actual value display as well as min/max display and accuracy class 0.5 FS and measuring
units bar.
4.1 Device view, buttons and functions
Display: 4½ digit display. Display of measured values
4.2 Installation / inserting/changing the battery
The batteries are included in the delivery and are not installed in the device yet. The batteries must be inserted before use.
- Slide the protective rubber cap backwards over the housing.
- Open the back of the device (3 x Allen key 2.5 mm) and remove the battery compartment.
- Insert batteries (2x AA 1.5V) into the battery compartment with the correct polarity.
- Put the battery case back into the device.
Note: The power supply cables are designed to be routed over the top anchorage of the screw
- Closing the device: reattach the cover with the screws
- Press the protective rubber cap over the device from behind.
The battery compartment on the back
of the device can be found under point 3.1

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4.3 Calibration
Press and hold the On/Off button for 5 seconds while the calibration is carried out.
Note: It is recommended to calibrate the manometer before each use, since a value in the mbar range is almost always displayed
as a result of temperature and environmental conditions.
5. Care and Storage
In order to enable effective work, we have designed the diagnostic tool to be low-maintenance. However, you should note a few points.
This promotes trouble-free operation and preserves the value of the technology.
A notice:
Damage to the diagnostic tool, the digital manometer or individual components due to aggressive cleaning agents or solvents.
Do not use aggressive or abrasive cleaning agents, solvents or other similar chemicals for cleaning.
- Keep dust and dirt away from the diagnostic tool.
- Clean the digital manometer with a soft, slightly damp cloth.
- Store your product in a dry and dust-free environment.
- Avoid places with high temperatures and humidity, or places that can get wet, also during maintenance and care.
- The device warranty is 12 months.
- Replace the batteries of the device as soon as “LOBAT” appears on the display.
- Keep the original packaging for transport to avoid damage.
6. Environmentally friendly disposal
Recycling according to WEEE (EU Directive 2002/96 EG)
You have the option of returning the diagnostic tool to us for disposal.
This diagnostic tool or it´s components must not be disposed of as residual waste.
If you do not return the diagnostic tool to us for disposal, you are obliged to take the device to a specialized center for separate collection and
disposal of hazardous materials and hazardous waste. The digital pressure gauge contains an electronic circuit board and batteries. These
parts must be removed before the device is scrapped. Used batteries can, for example, be returned free of charge to municipal collection
points or to retailers.
7. Technical data, specifications (pressure gauge)
Feature
unit
Measuring
range/description
Feature
unit
Measuring
range/description
Pressure range
bar
-1…+3
Temperature-compensated area
°C
+10…+40
Ambient temperature range
°C
-10…+50
Errors in the temperature-
compensated area
% FS /
°C
±0,02
Storage temperature
°C
-20…+60
Minimum load cycles
-
10 x 106
Medium temperature
°C
-20…+120
Supply
-
2 x 1,5 VDC LR6-
AA
Maximum relative humidity
% r.F
85
Maximum battery life
h
1500
Material pressure
connection
-
brass
Display
bar
LCD
Material membrane
-
ceramic
Pressure connection
-
Plug DN5
Material seal
-
H-NBR
Weight
g
ca. 390
Housing diameter with
protective rubber cap
mm
approx. 80
Housing diameter with protective
rubber cap
mm
approx. 95…100
8. Instruction manual (pressure gauge)
The operating instructions for the pressure gauge -1 ... +3 bar are available for download under the following link:
Link: https://www.autotestgeraete.de/fileadmin/website/autotestgeraete/website/BTS/BA_DD04_01_BTS.pdf

Operating instructions
Turbocharger Diagnostic Tool MESS02, operating instructions MESS02 Seite 9von 9
en
Technical changes reserved. 08/2022
BTS Turbo GmbH, Paradeisstr. 56, 82362 Weilheim, Deutschland
WWW.BTS-TURBO.DE