Charge Air System, Checking For Leaks, Vehicles With A Turbocharger

WARNING: This page is about a different car, the 2015 Audi A7 Quattro and 2014 Audi A7 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Turbo System Tester Kit VAG1687 with Turbo System Tester Kit - Adapter 11 VAG1687/11, Turbo System Tester Kit - Adapter 161687/16 and Turbo System Tester Kit - Adapter 171687/17

Procedure

NOTE:

Follow all the rules of cleanliness, refer to CLEAN WORKING CONDITIONS .

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

-- Open the clamps -arrows- and remove the air guide pipe -1-.

Fig 1: Identifying Air Guide Pipe & Clamps

GWWA23-10600

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Depending on the vehicle equipment level and market-specific crankcase ventilation hose may be used, which cannot be removed from the cylinder head cover without being destroyed. In these versions the hose on the cylinder head cover is destroyed and replaced.

-- Remove the hose -1- for the crankcase ventilation, to do so - if equipped- press the release button or the damage the hose connection on the cylinder head cover.

Fig 2: Identifying Crankcase Ventilation Hose

GWWA15-10987

Courtesy of AUDI OF AMERICA, LLC

-- Connect the connector for the crankcase ventilation to the turbocharger with Turbo System Tester Kit - Adapter 17 VAG1687/17.

Fig 3: Identifying Adapter VAG1687/17

GWWA21-10649

Courtesy of AUDI OF AMERICA, LLC

-- Connect the Adapter VAG1687/3 with the Adapter VAG1687/16 to the turbocharger.

Fig 4: Identifying Adapter VAG1687/3 And Adapter VAG1687/16

GWWA21-10650

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the hose clamp -arrow- and remove the air guide hose.

Fig 5: Identifying Clamp And Air Guide Hose

GWWA21-10698

Courtesy of AUDI OF AMERICA, LLC

-- Connect the Turbo System Tester Kit - Adapter 11 VAG1687/11 on the air guide hose to the Throttle Valve Control Module -J338-.

Fig 6: Identifying Adapter VAG1687/11

GWWA21-10651

Courtesy of AUDI OF AMERICA, LLC

-- Connect the hose -1- for the Turbo System Tester Kit VAG1687 to the adapter.

Prepare the Turbo System Tester Kit VAG1687 as follows:

Fig 7: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

GWWV21-0168

Courtesy of AUDI OF AMERICA, LLC

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

The rotary knob must face upward so the pressure control valve -2- can be turned.

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

NOTE:

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

-- Open the valve -3-.

CAUTION:

Damage could result if the pressure is set too high.

Pressure must not exceed 0.5 bar!

-- Set the pressure to 0.5 bar (7.2 psi) using the pressure control valve -2-.

-- Open the valve -4- and wait until the test circuit is filled. Regulate the pressure to 0.5 bar (7.2 psi) again if necessary.

-- Listen, feel and use commercially available leak detection spray or the Ultrasonic Tester VAG1842 to check the charge air system for leaks.

NOTE:

A small quantity of air dissipates via valves in engine. A pressure retention test is not possible for this reason.

For information on using the Ultrasonic Tester VAG1842S, refer to the Owner's Manual.

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

Assembling

Assemble in reverse order of disassembling. Note the following:

NOTE:

Replace the seal and O-rings.

Tightening Specifications

Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS