Charge Air System, Checking For Leaks

Special tools and workshop equipment required

Turbo System Tester Kit: VAG1687

Fig 1: Identifying Turbo System Tester Kit
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Turbo System Tester Kit - Adapter 6: VAG1687/6 and the Adapters: VAG1687/3 , : VAG1687/13-2 , : VAG1687/15

Fig 2: Identifying Turbo System Tester Kit
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Ultrasonic Tester: VAG1842S

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Leak detection spray, commercially available

Procedure

Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

Audi A4/A5:

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-- Remove the bolts -arrows- and the air guide -2-.

-- Loosen the hose clamps -arrows-.

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-- Remove the vacuum hose -2- and air duct pipe -1-.

Audi Q5:

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-- Remove the bolts -arrows- and air duct -1-.

-- Remove the vacuum hose -2- at the same time to not damage it.

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-- Loosen the hose clamps -arrows- and remove the air duct pipe -1-.

Continuation for All Vehicles:

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-- Install the Turbo System Tester Kit - End Seal: VAG1687/6 and Turbo System Tester Kit - Adapter: VAG1687/13-2 on the turbocharger.

CAUTION:

Risk of damaging the coupling due to improper handling.

- Coupling must not be bent more than 10°.

- Do not load the coupling on the cable.

-- Loosen the front clamping sleeve -arrows- and push toward the rear.

Fig 3: Identifying Bolts

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-- Slightly lower the front muffler -2- and secure as shown with a cable tie -1-.

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-- Seal the front muffler with Turbo System Tester Kit - Adapter: VAG1687/3 and Turbo System Tester Kit - Adapter: VAG1687/15 .

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-- Connect the Turbo System Tester Kit: VAG1687 to the Turbo System Tester Kit - Adapter 6: VAG1687/6 using the connection -5-.

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-- Completely remove the pressure regulating valve -2- and close the valves -3- and -4-.

Pull the knob in order to rotate the pressure regulating valve -2-.

-- Connect the Turbo System Tester Kit: VAG1687 to compressed air -1- with a commercially available intermediate piece.

-- Drain the water in the viewing glass via the water drain plug -6-.

-- Open the valve -3-.

CAUTION:

Risk of damaging the components if the pressure is set too high.

- Never set the test pressure above the specified adjustment.

-- Set the pressure to 0.2 bar (2.9 psi) using the pressure regulating valve -2-.

-- Open the valve -4- and wait until the test circuit is filled. Regulate the pressure to 0.2 bar (2.9 psi) again if necessary.

-- Check the charge air system for leaks by listening, feeling and using commercially available leak detection spray or the Ultrasonic Tester: VAG1842S .

A small quantity of air dissipates via the valves in the engine. For this reason a pressure retention test is not possible.
Refer to the Operating Instructions for information on using the Ultrasonic Tester: VAG1842S .

Assembling

Assembly is performed in reverse order.

Release the pressure in the test circuit by pulling off the coupling before removing the adapter.
Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Electronic Parts Information (ETKA).

-- Install the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

Tightening Specifications

Refer to OVERVIEW - AIR FILTER HOUSING
Refer to OVERVIEW - MUFFLER
Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS