Somebody asked about boost leak testers yesterday. Here's my DIY kit
06-03-2003, 01:31 PM
#1
AudiWorld Super User
Thread Starter
Somebody asked about boost leak testers yesterday. Here's my DIY kit
I put this kit together some time ago more as a Saturday project. I'd say the hardest part was finding the right size parts, but Home Depot had more than enough PVC end caps to go through.
Bear in mind that the typical disclaimers apply. In using a kit like this, you're intentionally pressurizing the air intake system and I will not take responsibility for those of you who get bonked in the head when a pvc end cap flies off because you didn't tighten it right. Also, make sure you keep an eye on the pressure to which you are filling the intake system. I wouldn't go above 10psi, even though most of us are generating almost 2x that or more, simply because even at 7-10 psi, you can hear a leak if one exists. I'd hate to hear that you screwed something up by failing to regulate pressure appropriately. That said, here's my kit:
Starting on the left and going clockwise:
1. PVC endcap with an NPT fitting and tire valve stem. Outer diameter of cap = 2.72" verified with calipers.
2. PVC endcap, same size as 1, but unmodified
3. Air compressor (mine runs off 12v power plug)
4. Small PVC endcap, Outer diameter = 0.85"
<img src="http://home.earthlink.net/~andrewaranda/audi/kit.jpg">
One of the endcaps is modified using the following items
5. 1/8-27 NPT thread tap
6. 17/64" drill
7. tire valve stem
8. 1/8-27 NPT to 1/4" hose barb fitting
9. hose clamp (not shown)
10. thread sealer (not shown)
<img src="http://home.earthlink.net/~andrewaranda/audi/parts.jpg">
Drill a hole in the top center of one of the caps and tap the threads. Insert fitting in the cap with thread sealer. Once this cures, then insert the tire valve stem onto the hose barb and clamp with hose clamp. I put some thread sealer in here as well to make sure I had a good seal.
The finished product looks like this:
<img src="http://home.earthlink.net/~andrewaranda/audi/valve_stem_plug.jpg">
This modified cap goes in the turbo intake hose, item 4 below, at the opening where it is usually connected to the air cleaner box (where the hose clamp is shown next to the number 5).
The smaller cap goes in the opening where the PCV valve #10 goes (so we don't pressurize the crankcase).
<img src="http://home.earthlink.net/~andrewaranda/audi/intake1.gif">
Lastly, the unmodified cap goes into the hose (#4 below) that connects to the throttle body at the point where it connects to the throttle body.
<img src="http://home.earthlink.net/~andrewaranda/audi/intake2.gif">
That's it, once all 3 caps are in place, connect the air compressor to the valve stem and turn it on until it gets to 7-10 psi. It should hold most of the pressure when you turn the compressor off. The intake tube has additional ports leading to the wastegate regulator and EVAP purge regulator valve, so it won't hold the pressure like a basketball would, but at that pressure, you will defintely hear any leaks.
Bear in mind that the typical disclaimers apply. In using a kit like this, you're intentionally pressurizing the air intake system and I will not take responsibility for those of you who get bonked in the head when a pvc end cap flies off because you didn't tighten it right. Also, make sure you keep an eye on the pressure to which you are filling the intake system. I wouldn't go above 10psi, even though most of us are generating almost 2x that or more, simply because even at 7-10 psi, you can hear a leak if one exists. I'd hate to hear that you screwed something up by failing to regulate pressure appropriately. That said, here's my kit:
Starting on the left and going clockwise:
1. PVC endcap with an NPT fitting and tire valve stem. Outer diameter of cap = 2.72" verified with calipers.
2. PVC endcap, same size as 1, but unmodified
3. Air compressor (mine runs off 12v power plug)
4. Small PVC endcap, Outer diameter = 0.85"
<img src="http://home.earthlink.net/~andrewaranda/audi/kit.jpg">
One of the endcaps is modified using the following items
5. 1/8-27 NPT thread tap
6. 17/64" drill
7. tire valve stem
8. 1/8-27 NPT to 1/4" hose barb fitting
9. hose clamp (not shown)
10. thread sealer (not shown)
<img src="http://home.earthlink.net/~andrewaranda/audi/parts.jpg">
Drill a hole in the top center of one of the caps and tap the threads. Insert fitting in the cap with thread sealer. Once this cures, then insert the tire valve stem onto the hose barb and clamp with hose clamp. I put some thread sealer in here as well to make sure I had a good seal.
The finished product looks like this:
<img src="http://home.earthlink.net/~andrewaranda/audi/valve_stem_plug.jpg">
This modified cap goes in the turbo intake hose, item 4 below, at the opening where it is usually connected to the air cleaner box (where the hose clamp is shown next to the number 5).
The smaller cap goes in the opening where the PCV valve #10 goes (so we don't pressurize the crankcase).
<img src="http://home.earthlink.net/~andrewaranda/audi/intake1.gif">
Lastly, the unmodified cap goes into the hose (#4 below) that connects to the throttle body at the point where it connects to the throttle body.
<img src="http://home.earthlink.net/~andrewaranda/audi/intake2.gif">
That's it, once all 3 caps are in place, connect the air compressor to the valve stem and turn it on until it gets to 7-10 psi. It should hold most of the pressure when you turn the compressor off. The intake tube has additional ports leading to the wastegate regulator and EVAP purge regulator valve, so it won't hold the pressure like a basketball would, but at that pressure, you will defintely hear any leaks.
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