Charge Air System, Checking For Leaks

Special tools and workshop equipment required 

• Turbo System Tester Kit :VAG1687 
• Turbo System Tester Kit - Adapter 6 :VAG1687/6  and the Adapters :VAG1687/3  , :VAG1687/13-2  , :VAG1687/15 

Procedure 

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

-- Remove the bolts -arrows- and air duct -1-.

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-- Remove the vacuum hose -2- at the same time to not damage it.

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Vehicles with Secondary Air System:

-- Press the release buttons on both sides and remove the secondary air injection hose -3-.

Continuation for All Vehicles:

-- Loosen the hose clamps -arrows- and remove the air duct pipe -1-.

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

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Fig 1: Identifying Bolts

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

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-- 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  to the :VAG1687/6  using the connection -5-.

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All additional procedures are described. Refer to the appropriate service information .

Assembling 

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

• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

Tightening Specifications 

• Refer to OVERVIEW - AIR FILTER HOUSING
• Refer to OVERVIEW - MUFFLER
• Refer to the appropriate service information .
• Refer to OVERVIEW - BUMPER COVER .