CHARGE AIR SYSTEM, CHECKING FOR LEAKS, WITHOUT Vehicle Diagnostic Tester

WARNING: This page is about a different car, the 2016 Volkswagen Touareg and 2015 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Turbo System Tester Kit: VAG1687
Turbo System Tester Kit - Adapter 3: VAG1687/3
Turbo System Tester Kit - Adapter 11: VAG1687/11
Turbo System Tester Kit - Adapter 16: VAG1687/16
Turbo System Tester Kit - Adapter 17 : VAG1687/17

Procedure

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Loosen the hose clamps -arrows- to remove the air duct pipe.

Fig 1: Air Guide Pipe, Remove/Install

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-- Remove the crankcase ventilation hose -1- from the turbocharger. Press the releases to do this.

Fig 2: Identifying Crankcase Ventilation Hose

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NOTE:

Depending on the market-specific vehicle version, crankcase ventilation hoses may be used that cannot be removed from the cylinder head cover without being destroyed.

Do not remove the hose on the cylinder head cover.

-- Connect the connector for the crankcase ventilation to the turbocharger with : VAG1687/17 .

Fig 3: Identifying Adapter VAG 1687/17

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-- Connect the : VAG1687/3 with the : 1687/16 to the turbocharger.

Fig 4: Identifying Adapter VAG 1687/3 And Adapter VAG 1687/16

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-- Loosen the hose clamp -top arrow- to remove the air guide hose from the Throttle Valve Control Module -J338-.

Fig 5: Charge Air Hose Clamps -Arrows- And Hose

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NOTE:

Ignore -bottom arrow-.

-- Connect the : VAG1687/11 on the air duct hose to the Throttle Valve Control Module -J338-.

Fig 6: Identifying Adapter VAG 1687/11

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-- Connect the hose -1- from the : VAG1687 to the adapter.

Prepare the : VAG1687 as follows:

Fig 7: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

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-- Completely remove the pressure regulating valve -2- and close the valves -3 and 4-.

The knob must face upward so the pressure regulating valve -2- can be turned.

-- Connect the : VAG1687 to compressed air -1- with a commercially available intermediate piece.

NOTE:

If there is water in the viewing glass, drain it through the water drain plug -6-.

-- Open the valve -3-.

CAUTION:

There is a risk of damage if the pressure is set too high.

The pressure must not exceed 0.5 bar!

-- Set the pressure to 0.5 bar (7.2 psi) using the pressure regulating valve -2-.

-- Open the valve -4- and wait until the test circuit is filled. Regulate the pressure to 0.5 bar (7.2 psi) again if necessary.

-- Listen, feel and use commercially available leak detection spray or the : VAG1842 to check the charge air system for leaks.

NOTE:

Refer to the Owner's Manual for information on using the : VAG1842S .

Release the pressure in the test circuit by removing the hose coupling before removing the adapter.

Installing

Assemble in the reverse order of removal. Note the following:

-- Check the O-rings for damage and replace if necessary.

Tightening Specifications:

Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS
Refer to OVERVIEW - CHARGE AIR SYSTEM