Charge Air System, Checking For Leaks

WARNING: This page is about a different car, the 2013 Volkswagen Beetle and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Adapter VAG 1687/5
Testing Unit for Turbocharger VAG 1687
Ultrasonic Measuring Device VAG 1842 or Commercially Available Leak Detection Spray

Test Sequence

-- Remove the noise insulation. Refer to REMOVAL AND INSTALLATION .

-- Release the clamp -A- and disconnect the hose -B- from the charge air pipe.

Fig 1: Identifying Charge Air Hose Locking Clip

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the adapter VAG 1687/5 to the charge air hose -A- and rotate it around approximately 90° -B-.

Fig 2: Connecting Adapter VAG 1687/5 To Charge Air Hose And Rotate It Around Approx. 90 Degrees

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Prepare the testing unit for turbocharger VAG 1687 as follows:

Fig 3: Connecting Pressurized Air Hose To Testing Unit For Turbocharger VAG 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Turn out the pressure regulator valve -2- counterclockwise until it stops (in the closed position).

-- Close the valves -3- and -4-.

NOTE:

In order to be able to turn the pressure regulator valve -2-, the rotary knob must be pulled upward.

-- Connect the testing unit for turbocharger VAG 1687 as shown.

Fig 4: Connecting Testing Unit For Turbocharger VAG 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect a compressed air hose -1- (pressurized air supply) to the testing unit for turbocharger VAG 1687.

Fig 5: Connecting Pressurized Air Hose To Testing Unit For Turbocharger VAG 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

If water is located in the viewing glass, drain it via the water drain plug -6-.

-- Open the valve -3-.

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

CAUTION:

Pressure must not exceed 0.5 bar! A pressure set too high may damage the engine.

-- Open the valve -4- and wait until the testing circuit has filled. If necessary, continue to regulate pressure to 0.5 bar.

-- Check the charge air system for poorly sealed areas by listening, feeling, using a leak detection spray or by using the ultrasonic measuring device VAG 1842.

NOTE:

Charge air hose installing. Refer to CHARGE AIR HOSE, DISCONNECTING AND CONNECTING .

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

Handling instructions of the ultrasonic measuring device VAG 1842. Refer to the operating instructions.

Before removing the adapter, discharge the pressure in the testing circuit by pulling off the coupling from the adapter VAG 1687/5.

Hose connections and charge air system hoses must be free of oil and grease before installing.