EGR Cooler, Checking For Leaks
Special Tools And Workshop Equipment Required
- Turbo System Tester Kit:VAG1687
- Turbo System Tester Kit - Adapter 11:VAG1687/11
- Turbo System Tester Kit - Adapter 15:VAG1687/15 for exhaust pipes 60 mm and 65 mm diameter
- Turbo System Tester Kit - Adapter 16:VAG1687/16 for exhaust pipe 55 mm diameter
- Cooling System Tester - Directional Valve:VAS691005/1
- Cooling System Tester - Directional Valve:VAS691005/5
- Turbocharger Tester Kit:VAG1397A
Test Conditions
- Coolant temperature must be at least 40 °C (104 °F).
:VAG1397A , Connecting:
-- Attach the :VAS691005/5 to the coolant expansion tank.
-- Attach the :VAS691005/1 to the :VAS691005/5 .
-- Connect the valve -1- for connection >>C<< and open the valve -2- for connection >>A<<.
-- Connect the hose from connection >>A<< from the Directional Valve to the connection >>II<< on the : VAG1397A .
-- Set the : VAG1397A to switch setting >>II<< (relative pressure measurement) and turn it on. The >>II<< must be visible.
:VAG1687 , Connecting:
-- If equipped, unclip the cable to the exhaust door control unit -1-.
-- Loosen the clamping sleeve -2- on the exhaust pipe and slide it toward the rear.
-- On vehicles without a tunnel brace the exhaust pipe -1- must be tied upward using a tensioning strap -2-.
-- Connect the :VAG1687/11 with hose -A- on the exhaust pipe (engine-side). Secure the hose with hose clamps.
Use the hose -A- for the exhaust pipes with 55 mm diameter = :VAG1687/16 .
Use the hose -A- for the exhaust pipes with 60 mm or 65 mm diameter = :VAG1687/15 .
-- Connect the :VAG1687 to :VAG1687/11
Prepare the :VAG1687 as follows:
-- Pull the pressure regulating valve -2- upward and remove completely, close the valves -3 and 4-.
-- Connect the :VAG1687 to compressed air -1- with a commercially available intermediate piece.
-- If there is water in the viewing glass, drain it through the water drain plug -6-.
-- Open the valve -3-.
- The pressure must not exceed 0.5 bar (7.2 psi)!
-- 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.
- A small quantity of air dissipates via the valves in the engine. For this reason a pressure retention test is not possible.
:VAG1397A , Reading
- Watch the Turbocharger Tester Kit for approximately five minutes.
- The pressure displayed on the Turbocharger Tester Kit must not increase.
-- If the pressure increases on the Turbocharger Tester Kit, compressed air is leaking from the exhaust side in the cooling system. The EGR cooler is leaking. Replace the EGR cooler.
- By cooling the coolant, a vacuum can result on a sealed EGR cooler. The vacuum is displayed on the Turbocharger Tester using a >>negative<< symbol.
:VAS691005/1 , Cleaning:
- After completing the leak test, the :VAS691005/1 must be cleaned to remove any entrapped moisture.
-- Insert the cleaning nozzle -D- in the hose from connection -A- on the Directional Valve.
-- Connect the :VAS691005/5 of the hose of the connector -B-.
-- Connect the pressure hose to the connection -C-.
-- Open the shut-off valves and blow through the hose for approximately 15 seconds.