Charge Air System, Checking For Leaks

WARNING: This page is about a different car, the 2016 Audi A3 and 2015 Audi A3. However, it is still accessible from the selected car via links, so may be relevant.

The water-cooled charge air cooler is integrated in the intake manifold (shared component).

Special tools and workshop equipment required

Turbo System Tester Kit: V.A.G 1687

Fig 1: Identifying Turbo System Tester Kit
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Turbo System Tester Kit - Adapter 11: V.A.G 1687/11
Turbo System Tester Kit - Adapter: V.A.G 1687/15
Cooling System Tester - Directional Valve: VAS 691 005/1

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Cooling System Tester - Directional Valve: VAS 691 005/5
Digital Pressure Sensor: V.A.G 1397B

Fig 2: Identifying Turbocharger Tester V.A.G 1397 A
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Hose Clip Pliers: VAS 6362

Fig 3: Hose Clip Pliers
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Engine Bung Set: VAS 6122

Fig 4: Engine Bung Set
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Procedure

Turbocharger Tester Kit: V.A.G 1397A , Connecting:

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

-- Attach the Cooling System Tester - Directional Valve: VAS 691 005/5 to the coolant expansion tank.

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-- Attach the Cooling System Tester - Directional Valve: VAS 691 005/1 to the Cooling System Tester - Directional Valve: VAS 691 005/5 .

-- Connect the valve -1- for connection >>C<< and open the valve -2- for connection >>A<<.

-- Connect the hose from connection >>A<< from the Directional Valve to the connection >>II<< on the Turbocharger Tester Kit: V.A.G 1397A .

-- Set the Turbocharger Tester Kit: V.A.G 1397A to switch setting >>II<< (relative pressure measurement) and turn it on. The >>II<< must be visible.

Turbo System Tester Kit: V.A.G 1687 , Connecting:

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-- Free up the vacuum hoses -arrows-.

-- Loosen the hose clamps -1 and 2- and remove the air duct pipe.

-- Remove the vent pipe for the crankcase ventilation -arrow-.

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-- Seal the connection with a plug -1- from the Engine Bung Set: VAS 6122 . Secure the plug with a hose clamp -2-.

-- Connect the Turbo System Tester Kit - Adapter 11: V.A.G 1687/11 with the Turbo System Tester Kit - Adapter : V.A.G 1687/15 to the turbocharger.

Fig 5: Identifying Turbo System Tester Kit - Adapter 11

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-- Connect the Turbo System Tester Kit: V.A.G 1687 to the adapter.

Prepare the Turbo System Tester Kit: V.A.G 1687 as follows:

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-- Pull the pressure regulating valve -2- upward and remove completely, close the valves -3- and -4-.

-- Connect the Turbo System Tester Kit: V.A.G 1687 to compressed air -1- with a commercially available intermediate piece.

-- If there is water in the viewing glass -6-, drain it through the drain plug.

-- Open the valve -3-.

CAUTION:

There is a risk of damage if the pressure is set too high.

- The pressure must not exceed 0.5 bar (7.25 psi)!

-- Set the pressure to 0.5 bar (7.25 psi) using the pressure regulating valve -2-.

-- Open the valve -4- and wait until the test circuit is filled. Regulate the pressure to 0.5 bar (7.25 psi) again if required.

A small quantity of air dissipates via valves in engine and the EGR cooler. For this reason a pressure retention test is not possible.
Refer to the Owner's Manual for information on using the Ultrasonic Tester : V.A.G 1842S .

-- Check the charge air circuit for leaking areas:

By listening
By feeling
by commercially available leak detection spray
With the Ultrasonic Tester VAG1842S: V.A.G 1842S

If no leaks are found in the charge air circuit, check the water-cooled charge air cooler for leaks.

Turbocharger Tester Kit: V.A.G 1397A , Reading:

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-- The pressure must be set to 0.5 bar (7.25 psi) at the same time.

Watch the Turbocharger Tester Kit for approximately five minutes.
The pressure displayed on the Turbocharger Tester Kit must not increase.

-- If the pressure increases on the Turbocharger Tester Kit, compressed air is leaking in the cooling system.

-- The charge air cooler is leaking replace the intake manifold with charge air cooler.

By cooling the coolant, a vacuum can result on a sealed charge air cooler. The vacuum is displayed on the Turbocharger Tester using a >>negative<< symbol.

Cooling System Tester - Directional Valve: VAS 691 005/1 , Cleaning

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After completing the leak test, the Cooling System Tester - Directional Valve: VAS 691 005/1 must be cleaned to remove any entrapped moisture.

-- Insert the cleaning nozzle -D- in the hose from connection -A- on the Directional Valve.

-- Connect the Cooling System Tester - Directional Valve: VAS 691 005/5 on the hose from the connector -B-.

-- Connect the pressure hose to the connection -C-.

-- Open the shut-off valves and blow through the hose for approximately 15 seconds.

-- Release the pressure in the test circuit by removing the hose coupling before removing the adapter.

Assembling

Assembly is performed in reverse order.

TIP:

Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.

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

Tightening Specifications

Refer to OVERVIEW - AIR FILTER HOUSING