AUDI A3 1995 8L / 1.G AEB ATW Engines Turbocharger System Owner's Manual

21-16

Note:

To help find small leaks, BEFORE pressurizing
the system fill system with smoke using special
tool KLI9210 and adapter KLI9210/50 as
described on page Page 21
-16
.

An ultrasonic detector may also be used to
detect extremely small leaks where smoke may
not be visible.

Special tool KLI9210 (Evaporative system
leak detector), connecting to 1.8L Turbo

- Install optional fitting LKI9210/50 on hose of
special tool KLI9210.

Special tool KLI9210 (Evaporative system leak detector), connecting
to 2.7L BiTurbo - Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached
to VAG 1687/1 at arrow on 1.8L Turbo).
- Install optional fitting LKI9210/50 on hose of special tool KLI9210.

-
Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached
Pa
ge 21 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

to VAG 1687/1 at arrow on 2.7L BiTurbo).
Pa
ge 22 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-17

Special tool LKI9210 (Evaporative system
leak detector), preliminary set-up

- Connect smoke generator leads to vehicle
battery.

With system filled with smoke:
Special tool VAG 1687, connecting to pressure adapter VAG 1687/1
(1.8L Turbo)
For illustrations purposes VAG is shown lying in the engine compartment.
In practice the tool should be hung from the hood. - Turn valve to test -black arrow-.
- Press smoke generator button to fill system with smoke (see
instructions printed on tester).
- Remove smoke generator hose and connect VAG1687 quickly to
prevent smoke from leaking out Page 21
-17
.
- Connect VAG 1687 quickly to prevent smoke from leaking out.

VAG 1687 is shown connected to VAG 1687/1 -black arrow-
Shop air supply will be connected to VAG 1687 -at white arrow-
- Perform pressure test Page 21
-19
.
Pa
ge 23 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-18

Special tool VAG 1687, connecting to
pressure adapter VAG 1687/1 (2.7L BiTurbo)
For illustrations purposes VAG is shown lying in
the engine compartment. In practice the tool
should be hung from the hood.

- Connect VAG 1687 quickly to prevent smoke
from leaking out.

VAG 1687 is shown connected to VAG 1687/1 -black arrow-
Shop air supply will be connected to VAG 1687 -at white arrow-
- Perform pressure test Page 21
-19
.
Pa
ge 24 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-19

Performing pressure test:

- With outlet hose -1- of VAG 1687 connected to air pressure adapter:
- Attach shop air supply line to previously installed male fitting ( Page
21
-14
.

CAUTION! - Open valve -3- between regulator valve and gauge.
- Adjust test pressure up to 0.5 bar ( CAUTION below) by turning
regulator valve -2-.
DO NOT pressurize the system above 0.5 bar!Doing so may force oil into the intake system which can damage
the engine.
- Slowly open outlet valve -4- (after gauge) to test hose connections.
- Observe pressure gauge for a drop in pressure.
Pa
ge 25 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-20

Note:
Some pressure will be lost past the throttle plate.

- Readjust test pressure to 0.5 bar ( CAUTION
above) by turning regulator valve -2-.
- Listen for any very large intake leaks.
If smoke generator was used to fill the system
with smoke:

- Inspect intake system connections for smoke at
leaks.

Note:
An ultrasonic detector may also be used to
detect extremely small leaks where smoke may
not be visible.

- Repair any leaks found.

- Remove tester.

- Remove plug from crankcase ventilation hose.

- Remove air pressure adapter.
Pa
ge 26 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

With VAS 5051 diagnostic tool connected:

- Erase DTC memory.
If smoke generator was not used to fill the
system with smoke:

- Apply soapy water solution or equivalent to
intake system connections.
Pa
ge 27 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-21

Note:
An ultrasonic detector may also be used to
detect extremely small leaks.

- Inspect intake system connections for leaks.

- Repair any leaks found.

- Remove tester.

- Remove plug from crankcase ventilation hose.

- Remove air pressure adapter.
With VAS 5051 diagnostic tool connected:

- Erase DTC memory.
Pa
ge 28 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

21-22

Rules of cleanliness


CAUTION!

Whenever carrying out any work on the fuel
supply or fuel injection systems, always
observe the following rules of cleanliness.
1. Thoroughly clean fuel system line and hose
connections and the surrounding area before
disconnecting.
2. Place removed components on a clean
surface and cover. Use plastic sheeting or paper.
Do not use fluffy rags that could leave lint!
3. Carefully cover over or seal any components
that have been opened if repairs are not carried
out immediately.
4. Install only clean parts:


Do not remove replacement parts from the
packaging until immediately before they are
to be installed.

Do not use parts that have been stored
without packaging (e.g. in toolboxes, etc.).
5. When the fuel system is opened:

Pa
ge 29 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1

Avoid working with compressed air
whenever possible.

Avoid moving the vehicle if possible.
Pa
ge 30 of 50 Turbochar
ger s
ystem
11/18/2002 htt
p://127.0.0.1:8080/audi/servlet/Dis
play?action=Goto&t
yp
e=re
pair&id=AUDI.B5.GE02.21.1