EGR Cooler, 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.

Special Tools And Workshop Equipment Required

Turbo System Tester Kit:VAG1687
Turbo System Tester Kit - Adapter 11:VAG1687/11
Turbo System Tester Kit - Adapter 15:VAG1687/15 for exhaust pipes 60 mm and 65 mm diameter
Turbo System Tester Kit - Adapter 16:VAG1687/16 for exhaust pipe 55 mm diameter
Cooling System Tester - Directional Valve:VAS691005/1
Cooling System Tester - Directional Valve:VAS691005/5
Turbocharger Tester Kit:VAG1397A

Test Conditions

Coolant temperature must be at least 40 °C (104 °F).

:VAG1397A , Connecting:

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-- Attach the :VAS691005/5 to the coolant expansion tank.

-- Attach the :VAS691005/1 to the :VAS691005/5 .

-- 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 : VAG1397A .

-- Set the : VAG1397A to switch setting >>II<< (relative pressure measurement) and turn it on. The >>II<< must be visible.

:VAG1687 , Connecting:

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-- If equipped, unclip the cable to the exhaust door control unit -1-.

-- Loosen the clamping sleeve -2- on the exhaust pipe and slide it toward the rear.

-- On vehicles without a tunnel brace the exhaust pipe -1- must be tied upward using a tensioning strap -2-.

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-- Connect the :VAG1687/11 with hose -A- on the exhaust pipe (engine-side). Secure the hose with hose clamps.

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Use the hose -A- for the exhaust pipes with 55 mm diameter = :VAG1687/16 .

Use the hose -A- for the exhaust pipes with 60 mm or 65 mm diameter = :VAG1687/15 .

-- Connect the :VAG1687 to :VAG1687/11

Prepare the :VAG1687 as follows:

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

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

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

-- Open the valve -3-.

CAUTION:

- The pressure must not exceed 0.5 bar (7.2 psi)!

-- Set the pressure to 0.5 bar (7.2 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 (7.2 psi) again if necessary.

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

:VAG1397A , Reading

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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 from the exhaust side in the cooling system. The EGR cooler is leaking. Replace the EGR cooler.

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

:VAS691005/1 , Cleaning:

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After completing the leak test, the :VAS691005/1 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 :VAS691005/5 of the hose of 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.