Fuel System, Checking For Leaks

WARNING: This page is about a different variant/trim than selected.

Special Tools And Workshop Equipment Required

Evaporative Emissions Tester:KLI9210
Evaporative Emissions Tester - Adapter 55:KLI9210/55-1
Hose Clamps - Up To 25mm:3094

Connector	Color Marking on the Connector Coupling
Fuel supply	Black
Fuel Return Line	Blue
Ventilation	White or beige

:KLI9210 Preparation:

NOTE:

Depending on the version, the appearance of the :KLI9210 may vary.

-- Check on :KLI9210 whether there is enough fluid in the smoke generator.

-- Set the valve -D- to "Hold".

Fig 1: Checking Evaporative Emissions Tester KLI 9210 DLX To Determine Whether There Is Enough Fluid In Smoke Generator

Courtesy of AUDI OF AMERICA, LLC

-- Open the nitrogen bottle -H-.

-- Connect the measuring hose -G- to the self-test connection -B-.

-- Set the valve -D- to "Test".

-- Using the pressure reducer -J- adjust the pressure to 25 mbar (10 in. H₂ O).

-- Set the valve -D- to "Hold".

The pressure must now be maintained for a minimum of 2 minutes.

If the pressure is not maintained, check the tester.

Fuel System, Checking For Leaks:

Fig 2: Connecting Adapter For Evaporative Emission Tester KLI 9210/55-1 To Ventilation Line

Courtesy of AUDI OF AMERICA, LLC

-- Connect the :KLI9210/55-1 to the breather lines -A- "white markings" as illustrated.

-- Connect the measuring hose -G- on the :KLI9210 to the :KLI9210/55-1 .

Fig 3: Connecting Measuring Hose From Evaporative Emissions Tester KLI 9210 To Adapter For Evaporative Emission Tester KLI 9210/55-1

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-- Connect the :KLI9210 to the vehicle battery.

-- Remove right rear wheel housing liner.

-- Tightly close the hose to the air filter -arrow- using a hose clamp.

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-- Set the valve -D- to "Test". The fuel system is now filled.

Fig 4: Checking Evaporative Emissions Tester KLI 9210 DLX To Determine Whether There Is Enough Fluid In Smoke Generator

Courtesy of AUDI OF AMERICA, LLC

-- Watch the pressure gauge -C- and the flow meter -E-. If the flow quantity decreases and pressure increases to 10 in. H2O (25 mbar), the fuel system is full.

-- After the pressure has stabilized, set the valve -D- to "Hold".

After 5 minutes the pressure must not drop below 8 in. H2O (20 mbar).

If the Pressure Drops or If No Pressure Develops, Then Locate the Leak as Follows:

-- Set the valve -D- to "Test" and fill the system with smoke.

-- While fuel system is being filled, press smoke generator button -I- for approximately one minute.

The fuel system is now under pressure and filled with smoke.

-- Check all the lines, hoses and the fuel cap for escaping smoke.

NOTE:

Illuminate components and hoses with a strong flood light, the smoke will be more visible.

An ultrasonic sensor tester or commercially available leak spray can also be used to locate leaks.

Depending on how long fault finding lasts, the smoke generator button may need to be pressed again. This ensures there is enough smoke present in the fuel system.

It is necessary to open the assembly opening inside the passenger compartment to check the flange on the fuel pump and fuel filter.

Fig 5: Identifying Fuel Delivery Unit Cover

Courtesy of AUDI OF AMERICA, LLC

-- Replace any leaking hoses or components.