x1rider

After stripping a few hose clamps installing my intercooler, I decided to upgrade all the clamps to T-bolt clamps for the pipes and constant torque clamps for the intake (the intake hose tried slipping off the throttle inlet a few times). They have more than twice the width of normal hose clamps.

<img src="http://pictureposter.audiworld.com/107183/leaktest1.jpg">

It was a good time to do a leak pressure test while the bumper was off.
Here is what I needed for my home made kit: ABS glue, ABS dishwasher drain, ABS female adapter 2", ABS female adapter cap, 0-15psi pressure regulator, tire valve, Halloween fog machine, and an old shop-vac hose.
I got the pressure regulator from www.controlair.com. It's graded from 0-15psi which is great because Bentley says to pressurize the system only with 0.5 Bar (7.25psi).
I used the ABS female adapter with the cap as the intake hose plug. I drilled the cap and inserted the tire valve through the hole. I applied a very generous amount of ABS glue to the valve and the cap to make sure I had no air leak. The great thing with the valve is that you can pressurize the system using a tire inflating stem and you get no air reversal. For the crankcase breather connection plug I used an ABS dishwasher drain (3/4" diameter).

Pics of the intake plug and crankcase breather connection plug.

<img src="http://pictureposter.audiworld.com/107183/leaktest9.jpg">

Pic of the FOG MACHINE!!! (with the modified shop-vac hose)

<img src="http://pictureposter.audiworld.com/107183/leaktest8.jpg">

Pic of the pressure regulator with tire inflating stem.

<img src="http://pictureposter.audiworld.com/107183/leaktest5.jpg">

First thing to do is plug the crankcase breather connection on the TIP.

<img src="http://pictureposter.audiworld.com/107183/leaktest2.jpg">

Then you can use the fog machine and blow smoke into the system.

<img src="http://pictureposter.audiworld.com/107183/leaktest3.jpg">

Now connect the intake plug.

<img src="http://pictureposter.audiworld.com/107183/leaktest4.jpg">

Set the regulator for 7.25psi.

<img src="http://pictureposter.audiworld.com/107183/leaktest6.jpg">

Pressurize the system (follow Bentley's instructions).

<img src="http://pictureposter.audiworld.com/107183/leaktest7.jpg">

All you have to do is listen for leaks and watch for smoke to find out if there are any leaks.
Fortunately I had none, all I had to do was close everything up!!!

ps. I did this write-up for information only, try at your own risk!

skeeball

Awesome DIY and excellent writeup. Thank you!

MB The Body

wow that's awesome!

Pabblo

Very smart!

Tgr_Clw

cool

All Wheel Driver

if you're chipped, run it up to 20psi, then you'll see if it really leaks.

x1rider

you can do the tests at home, take corrective actions if needed and then test it again without having to go to a shop and paying them everytime you get the test done. I'll bet you that you pay for the parts needed to build your own with one single leak test done at the shop.

x1rider

Bentley seems pretty specific with the instructions (not pressurizing above 0.5 bar). So I decided to play it safe.



<img src="http://pictureposter.audiworld.com/107183/leak_test_instr..jpg">

skeeball

Plus you end up with a fog machine. And let me tell you, ladies love the fog machine.

x1rider

The FOG MACHINE gets them every time!!!