2018 Audi A5 Download Service & Repair Manual

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Repair Manual Audi 2014 ➤ Using the Evaporative Emissions Tester Edition 11.2016 Service Service Department. Technical Information

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. List of Workshop Manual Repair Groups Repair Group 20 - Fuel Supply Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. Service All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2017 Audi AG, Ingolstadt D3E804E33F4

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Contents 20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Fuel System EVAP Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Evaporative Emissions Tester KLI9210 , General Information . . . . . . . . . . . . . . . . . . . . . . 1 1.2 EVAP System Leak Test, Vehicles with Leak Detection Pump V144 (LDP) . . . . . . . . . . . . 4 1.3 EVAP System Leak Test, Vehicles with Fuel Tank Leak Detection Control Module (NVLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 Contents i

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 ii Contents

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. 20 – Fuel Supply 1 Fuel System EVAP Leak Test (Edition 11.2016) ⇒ “1.1 Evaporative Emissions Tester KLI9210 , General Infor‐ mation”, page 1 ⇒ “1.2 EVAP System Leak Test, Vehicles with Leak Detection Pump V144 (LDP)”, page 4 ⇒ “1.3 EVAP System Leak Test, Vehicles with Fuel Tank Leak Detection Control Module (NVLD)”, page 8 1.1 Evaporative Emissions Tester - KLI9210- , General Information ⇒ “1.1.1 General Information”, page 1 ⇒ “1.1.2 Evaporative Emissions Tester KLI9210 , Self-Test”, page 2 ⇒ “1.1.3 Evaporative Emissions Tester KLI9210 , Calibrate”, page 3 ⇒ “1.1.4 Method 1: Locate Leak with Smoke Generator”, page 3 ⇒ “1.1.5 Method 2: Locate Leak with Ultrasonic Tester”, page 3 1.1.1 General Information Special tools and workshop equipment required ♦ Evaporative Emissions Tester - KLI9210- ♦ Hose Clamps Up to 25 mm Dia. - VAS3094- ♦ Vehicle Diagnostic Tester Use of the following tools depend on the vehicle model being tes‐ ted: ♦ Evaporative Emissions Tester - Adapter 52 - KLI9210/52- ♦ Evaporative Emissions Tester - Adapter 54 - KLI9210/54- ♦ Evaporative Emissions Tester - Adapter 57 - KLI9210/57- The EPA-mandated leak detection threshold has changed over time from 1.0 mm (0.040 in.) to 0.5 mm (0.020 in.). These changes to EPA regulations regarding Evaporative Emission (EVAP) sys‐ tem integrity indicated that additional resources for more accurate EVAP system diagnosis are necessary. The Evaporative Emissions Tester - KLI9210- allows testing using nitrogen to pressurize the EVAP system. A smoke generator or ultrasonic tester is then used to locate the source of EVAP system concerns. The procedure in this chapter outline the general use of the Evap‐ orative Emissions Tester - KLI9210- . It is intended as a guideline, as EVAP systems vary between models. Testing LDP Equipped Vehicles with Leak Detection Pump - V144- Leak detection monitoring was implemented in vehicles begin‐ ning in MY 1998 with the Leak Detection Pump (LDP) Leak Detection Pump - V144- . Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 1. Fuel System EVAP Leak Test 1

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Refer to ⇒ “1.2 EVAP System Leak Test, Vehicles with Leak Detection Pump V144 (LDP)”, page 4 Testing NVLD Equipped Vehicles with Fuel Tank Leak Detection Control Module Starting in MY 2011, some vehicles began to employ the fuel tank leak detection control module to replace LDP for EVAP system monitoring. Refer to ⇒ “1.3 EVAP System Leak Test, Vehicles with Fuel Tank Leak Detection Control Module (NVLD)”, page 8 1.1.2 Evaporative Emissions Tester - KLI9210- , Self-Test Note ♦ Always perform system self-test of Evaporative Emissions Tester - KLI9210- prior to use to ensure that there are no leaks. ♦ Refer to Evaporative Emissions Tester - KLI9210- instruction manual for specific instructions. – Connect vehicle interface hose to self-test port -1-, ensuring that fitting is finger-tight. Over-tightening will damage fitting. – Turn control valve -2- to Test. Gauge -3- should read 14 ± 1 in. of water. If gauge does not read 14 ± 1 in. of water: – Verify that valve on EVAP tester nitrogen cylinder is open and that cylinder has sufficient pressure before continuing. – Turn fine adjust regulator knob (-arrow-) until gauge reads 14 in. of water; tighten lock nut. Note If gauge still does not read within above range, contact K-Line Customer Service - Technical Support for additional instructions before continuing. Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 2 Rep. Gr.20 - Fuel Supply

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. – Check flow meter -4-. Meter must indicate no flow. – Turn control valve to Hold position. – Check gauge. Gauge must hold pressure. If gauge leaks down: – Verify that vehicle interface hose is firmly seated and repeat previous six steps before continuing. If gauge continues to leak down: – Use ultrasonic tester to locate and repair leak before continu‐ ing. Refer to ⇒ “1.1.5 Method 2: Locate Leak with Ultrasonic Tester”, page 3 Note If the leak cannot be located or repaired, contact K-Line Customer Service - Technical Support. 1.1.3 Evaporative Emissions Tester - KLI9210- , Calibrate Determine vehicle leak threshold: To MY 2000 - leak threshold 0.040 in From MY 2001 - leak threshold 0.020 in – Attach test hose to appropriate preset port -black arrows-. – Turn control valve from “Hold to Test”. – Set flow meter flag -white arrow- at indicated value on flow meter. – Turn control valve to “Hold” then remove test hose. 1.1.4 Method 1: Locate Leak with Smoke Generator – Connect leads from smoke generator to vehicle battery. – Use smoke generator trigger to charge fuel system with smoke. – Inspect complete EVAP system for escaping smoke. 1.1.5 Method 2: Locate Leak with Ultrasonic Tester General search: tester only Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 1. Fuel System EVAP Leak Test 3

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Localized search: tester with extension -left in illustration- If leak cannot be located: – Disconnect and plug or clamp shut EVAP lines to isolate fuel tank, using Hose Clamps Up to 25 mm Dia. - VAS3094- or equivalent, before continuing. Caution Clamp only soft rubber lines when isolating a leak. To avoid risk of damage, never clamp hard plastic lines! If flow stops: – Reconnect EVAP lines to search area that was isolated. If leak or source of fuel odor cannot be found: – Contact Audi Dealer Technician Helpline. Caution Under no circumstances should the vehicle be returned to the customer without proper diagnosis and repair. When leak has been located: – Repair leak and repeat EVAP system test. – Perform quality check and return vehicle to customer. Note ♦ Because leak may be at top of fuel tank, it may not be possible to locate through fuel pump/sending unit access plate. ♦ Fuel tank may need to be lowered to locate the leak. 1.2 EVAP System Leak Test, Vehicles with Leak Detection Pump - V144- (LDP) ⇒ “1.2.1 EVAP System Test with Vehicle Diagnostic Tester ”, page 4 ⇒ “1.2.2 Fuel Cap, Testing”, page 5 ⇒ “1.2.3 Leak Detection Pump V144 , Testing for Internal Leaks”, page 5 ⇒ “1.2.4 EVAP System, Testing”, page 6 ⇒ “1.1.4 Method 1: Locate Leak with Smoke Generator”, page 3 ⇒ “1.1.5 Method 2: Locate Leak with Ultrasonic Tester”, page 3 1.2.1 EVAP System Test with Vehicle Diag‐ nostic Tester For vehicles with LDP: – Perform leak test using Vehicle Diagnostic Tester and “Basic Setting” mode. Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 4 Rep. Gr.20 - Fuel Supply

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. If vehicle fails above test (System not OK): – Verify fuel cap is properly closed and repeat test. If System OK after repeat test: – Erase Diagnostic Trouble Code (DTC) memory (if necessary). – Repeat test several times to ensure proper EVAP system op‐ eration. Remove and reinstall fuel cap before each test – Perform quality check and return vehicle to customer. Note If the vehicle passes the above EVAP system test, DTC may be sporadic; the entire EVAP system should be carefully inspected. If the Vehicle Diagnostic Tester continues to indicate “System not OK” after repeat test, proceed to next step. 1.2.2 Fuel Cap, Testing – Connect fuel cap tester to hose. – Screw fuel cap tightly to cap receiver -arrow-. – Turn control valve to “Test”. – Read flow meter on tester. If no flow is indicated: – Proceed to ⇒ “1.2.3 Leak Detection Pump V144 , Testing for Internal Leaks”, page 5 . If flow is indicated: – Replace fuel cap and re-test. If new fuel cap shows no flow: – Repeat leak test, with new fuel cap installed, using Vehicle Diagnostic Tester in “Basic Settings” mode. If Leak Test shows 'System OK": – Perform quality check and return vehicle to customer. 1.2.3 Leak Detection Pump - V144- , Testing for Internal Leaks If vehicle is not equipped with leak detection monitoring, proceed to ⇒ “1.2.4 EVAP System, Testing”, page 6 . – Clamp off LDP outlet (EVAP side) using Hose Clamps Up to 25 mm Dia. - VAS3094- or equivalent. Caution Clamp only soft rubber lines when isolating a leak. To avoid risk of damage, never clamp hard plastic lines! – Repeat leak test using Vehicle Diagnostic Tester and “Basic Setting” mode. Vehicle Diagnostic Tester should immediately indicate “System OK”. Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 1. Fuel System EVAP Leak Test 5

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. – Repeat test several times to verify result. If test continues to indicate “System OK”, remove clamp and pro‐ ceed to ⇒ “1.2.4 EVAP System, Testing”, page 6 . If Vehicle Diagnostic Tester indicates “System not OK”: – Replace LDP and repeat test. If Vehicle Diagnostic Tester indicates “System OK” after LDP is replaced and test result is verified: – Perform quality check and return vehicle to customer. 1.2.4 EVAP System, Testing – Plug or clamp LDP inlet (filter side) using Hose Clamps Up to 25 mm Dia. - VAS3094- or equivalent. – Attach fuel cap adapter to filler neck (-arrow-) and test hose to adapter. Audi 2014 ➤ Using the Evaporative Emissions Tester - Edition 11.2016 6 Rep. Gr.20 - Fuel Supply

2018 Audi A5 Download Service & Repair Manual

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