DIY: Test/Fix intercooler leaks w/bumper removal procedure

[Audi-RS6]

Hello everyone,

per someones request...

Goal of this DIY is to finally fix boost leak issue without buying new intercoolers,
i also thought that I'm fast until I met m5 on my way home...

I would recommend to read comments to the pictures, to save you from troubles (sorry for my english
just in case)...

lets start... ramp







I was able to turn wheels while on the ramp, its to gain access to the side bolts that hold the
bumper





... you dont have to remove completely plastic cover, just bent it to gain access









here are those bolt, there are three of them





...you better use this combination of tools



driver side









remove fog grill



one bolt on each side holds main bumper support











stop! unclipp the sides (next picture)











remove lower plastic cover screws...







now push the bumper and try to locate connectors for flog light and horn, unclipp em











driver side has a wate hose (I lost my clip last time, so I used ziptie)















remove everything thats attached to intercooler, if your car was never taken apart, you should have
some plastic covers behind each intercooler, remove them too (i dont have them)









lower hose





three screws hold the headlights...



















lower plastic bolt holds radiator hose







i managed to remove radiator with a flat screw driver, aluminum bents really well, so make sure
you dont punch a hole in it









stop! I forgot to remove lower side bolt for intercooler



now it should move







my test equipment (3" plumbing cap, 3" plumbing test cap, OEM air compressor, water)

IMPORTANT!!! with this test equipment u cannnot go higher than 1bar, or it will shoot the
yellow cap



leak, even after I fixed it 2 weeks ago...





driver headlight



magnetic tool











unplug all connectors to eliminate troubles





move all hoses and wires somewhere inside to have room for intercooler





lol again forgot to remove side lower bolt...





leak...



my first mistake!!! i tried to fix it fast and used minute epoxy (DONT DO IT)





leak agian after hour of wait



now i used JB welder, prepared the surface this time and waiting 12 hours for cure







to be continued...