Charge Air System, Checking For Leaks: Procedure

WARNING: This page is about a different car, the 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

-- Remove the engine cover. Refer to ENGINE COVER .

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

Fig 1: Identifying Crankcase Ventilation Hose And Bolt

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-- Disconnect the connector from the crankcase ventilation hose -1-.

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

-- Loosen the hose clamps -3- and remove the air guide pipe from the air filter housing.

-- Remove bolt -2- and tilt the air guide pipe with the intake manifold backward and remove from the turbocharger.

-- Remove the bolts -arrows-.

Fig 2: Identifying Pulsation Damper, Removal

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-- Loosen the hose clamps -1- and remove the pulsation damper -2-.

-- Install the Adapter 1687/12 into the intake hose -1- and secure it with a clamp.

Fig 3: Identifying V.A.G 1687

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Prepare the Turbocharger Testing Unit V.A.G 1687 as follows:

-- Fully turn out the pressure regulator valve -2- to the closed position and close the valves -3- and -4-.

Fig 4: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

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NOTE: Pull the knob in order to rotate the pressure regulating valve -2-.

-- Connect the Testing Unit for Turbocharger V.A.G 1687 as shown, to the Adapter 1687/12.

Fig 5: Identifying V.A.G 1687

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-- Connect the pressurized air hose -1- (pressurized air supply) to the Testing Unit for Turbocharger V.A.G 1687.

Fig 6: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

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

-- Open the valve -3-.

-- Set the pressure to 0.5 bar using the pressure control 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 test circuit is filled. Adjust the pressure to 0.5 bar if necessary.

-- Check the charge air system for leaks by/with:

Listening
Touching
Commercially available leak spray
Ultrasonic Measuring Device V.A.G 1842

NOTE:

Small leaks on the intake side of the turbocharger or permitted because the intake hoses are not designed for positive pressure.

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

Handling instructions of Ultrasonic Measuring Device V.A.G 1842. Refer to Owner's Manual.

If a poorly sealed area is discovered, observe the notes for charge air system when repairing.

Before removing adapter, discharge pressure in testing circuit by pulling off coupling from Adapter 1687/10.