Charge Air System, Checking For Leaks

Special tools and workshop equipment required

Procedure

-- Remove the engine cover -arrows-.

Fig 1: Identifying Engine Cover

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-- Press the release buttons and remove the crankshaft housing ventilation hose -1- from the cylinder head cover.

Fig 2: Identifying Air Guide Pipe & Components

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-- Free up the vacuum hoses -arrows- on the air guide pipe.

-- Loosen clamps -2- and -3- and remove the air guide pipe.

-- Remove bolts -arrows-.

Fig 3: Identifying Pulsation Damper, Removal

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-- Loosen hose clamp -1- and remove the pulsation damper.

-- Install the V.A.G 1687/12 into the air guide hose -1- and secure it with a clamp.

Fig 4: Identifying V.A.G 1687

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-- Connect the V.A.G 1687 to the adapter.

Prepare the V.A.G 1687 as follows:

-- Remove the pressure regulator valve -2- and close valves -3- and -4-.

Fig 5: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

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

-- Connect the V.A.G 1687 to compressed air -1- with a commercially available adapter piece.

NOTE:

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

-- Open the valve -3-.

CAUTION:

Damage could result if the pressure is set too high.

-- Set the pressure to 0.5 bar using the pressure control valve -2-.

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

-- Listen, feel and use commercially available leak detection spray or the ultrasonic tester V.A.G 1842 to check the charge air system for leaks.

NOTE:

A small quantity of air dissipates via valves in engine. A pressure retention test is not possible for this reason.

For information on using the V.A.G 1842

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

Assembling

Assembly is in reverse order of removal, note the following:

NOTE:

Replace the seal and O-ring.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps appropriate for the model.

In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

-- Install the pulsation damper. Refer to TURBOCHARGER ASSEMBLY OVERVIEW .