Charge Air System, Checking For Leaks

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Turbo System Tester Kit: VAG1687 with Turbo System Tester Kit - Adapter 6: VAG1687/6 and Turbo System Tester Kit - Adapters: VAG1687/3 , : 1687/10 , : 1687/11 , : 1687/12 , : VAG1687/13-2 , : VAG1687/15 .

Procedure

-- Observe the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Remove the air filter upper section. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the cap -2-.

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-- Release the retainer in direction of -arrow B- and remove the oil filler tube -1- upward from the air filter lower section.

-- Turn the oil filler tube counter-clockwise in direction of -arrow A- and remove it.

-- Close the oil filler tube with the cap.

-- Loosen the hose clamp -arrow- and remove the air duct pipe from the air filter housing.

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Vehicle with High-Voltage System:

Fig 1: Fuel Tank Pressure Sensor 2 -G850- Component Location

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-- Disconnect the connector -3-.

Continuation for All Vehicles:

-- Free up the EVAP system hose -2- from the air duct pipe.

Air Duct Pipe, Version 1:

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-- Remove the vacuum hose -2- (example illustration above).

-- Loosen the hose clamp -3- and remove the air duct pipe -1-.

Air Duct Pipe, Version 2:

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-- Remove the vacuum hose -3-.

-- Press the release buttons on both sides and remove the secondary air injection hose -4-.

-- Loosen the hose clamp -1- and remove the air duct pipe -2-.

Continuation for All Vehicles:

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-- Install the : VAG1687/6 and : VAG1687/13-2 on the turbocharger.

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-- Loosen the threaded connections -arrows- and slide the clamping sleeves toward the rear.

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CAUTION:

Risk of damaging the coupling due to improper handling.

- Coupling must not be bent more than 10°.

- Do not load the coupling on the cable.

-- Slightly lower the front muffler -2- and secure as shown with a cable tie -1-.

-- Seal the front muffler with the : VAG1687/3 and : VAG1687/15 .

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-- Connect the : VAG1687 with the connection -5- to the : VAG1687/6 .

Fig 2: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

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All additional procedures are described. Refer to CHARGE AIR SYSTEM, CHECKING FOR LEAKS .

Assembling

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

-- Install the air filter upper section. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

Tightening Specifications

Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS .
Refer to OVERVIEW - MUFFLER