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Thread: DIY: Basic boost leak test

  1. #1
    Registered User Audi-RS6's Avatar
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    Arrow DIY: Basic boost leak test

    Boost leak is an issue of turbo cars, especially when chipped.

    Boost leak may appear from turbo to y-pipe (#31 on dgrm)
    or
    from BPV (By Pass Valve) back to turbo - this rarely happens...

    Here is a boost system diagram

    You need to check (meaning remove and check):
    Passenger side
    #28 - lower hose (comes right after turbo)
    #20 - lower intercooler hose
    #26 - upper intercooler hose

    Driver side
    #27 - lower hose (comes right after turbo)
    #19 - lower intercooler hose
    #25 - upper intercooler hose

    Dont believe it could happen?
    here is what i found

    NOTE: no need bumper removal! i was doing other stuff on car...



    Upper



    Lower



    2nd lower hose





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  2. #2
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    Was this crack in the lower IC hose caused by some sort of road debris? Wear? Stress?

  3. #3
    Registered User Audi-RS6's Avatar
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    Dont know, what caused that hole to appear

    I noticed oil and grease in one spot of the hose, hole was not visible at first, since it was on another side of viewing angle, so i took that hose off and there it was

    Quote Originally Posted by DHall1 View Post
    Was this crack in the lower IC hose caused by some sort of road debris? Wear? Stress?
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  4. #4
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    would an effective quick check to see if intercoolers are leaking to shine a flashlight into the duct and look at the surface of the intercooler for traces of black soot?
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  5. #5
    Registered User Audi-RS6's Avatar
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    Well if you clean it and then you notice same black soot it definitely leaks, not sure if you willing to wait that long before it appears

    Quote Originally Posted by kismetcapitan View Post
    would an effective quick check to see if intercoolers are leaking to shine a flashlight into the duct and look at the surface of the intercooler for traces of black soot?
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  6. #6
    Registered User skribe's Avatar
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    90% chance one of your IC's is leaking. Usually passenger side first. At your car's age/mileage you would probably see oil along the seams just by looking.
    Minor leak in an IC doesn't kill performance as much as you might expect though. Only real way to check is remove, pressurize, submerge.

  7. #7
    Registered User V8weight's Avatar
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    Smoke test.....
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  8. #8
    Registered User hahnmgh63's Avatar
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    A bit of work but since you already have the front end off you could pull your intercoolers and with rubber plumbing caps plug both ends and intall a air fitting and measure leakdown. Obviously be careful and don't overpressure them as it wouldn't take much with a regular air compressor. That is how I checked mine, it was already obvious the passenger side was leaking so I did this to check the drivers side and found out there was a small leak at the seam. It was documented here a few years ago by someone and who did the first repairs but for the life of me I don't remember who and since I went to Wagners I don't think I'll ever have to worry about it again. Audi just went cheap with these Spanish or Portughese Intercoolers. Porsche never seems to have Intercooler leaks and they use German made coolers, it's sad Audi tries to save a few bucks. Years ago they went to Intercoolers with plastic side tanks just like most of the Radiators around now and have had a fair amount of leaking with those so the all Aluminum RS6 Intercoolers were going to be an upgrade before they went to a crappy manufacturer.
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  9. #9
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    I think it's a material issue - they're made of too fragile an alloy. The design itself is as good as it comes - bar and plate with nicely designed endtanks.
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