Charge Air System, Checking For Leaks

Special tools and workshop equipment required

Turbo System Tester Kit :V.A.G 1687

Fig 1: Identifying Turbo System Tester Kit
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Turbo System Tester Kit - Adapter 10 :V.A.G 1687/10 and Turbo System Tester Kit - Adapter :V.A.G 1687/14

Fig 2: Identifying Turbo System Tester Kit
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Ultrasonic Tester :V.A.G 1842S

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Leak detection spray, commercially available

Procedure

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

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

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

Fig 3: Identifying Clamps With Air Guide Pipe

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-- Connect the Turbo System Tester Kit - Adapter 10 :V.A.G 1687/10 -item 2- with Turbo System Tester Kit - Adapter 14 :V.A.G 1687/18-14 -item 1- on the turbocharger.

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-- Connect the Turbo System Tester Kit :V.A.G 1687 -item 3- to the adapter.

Preparing the Turbo System Tester Kit :V.A.G 1687 :

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-- Pull the pressure regulating valve -2- upward and remove completely, close the valves -3- and -4-.

-- Connect the Turbo System Tester Kit :V.A.G 1687 to compressed air -1- with a commercially available intermediate piece.

-- Drain the water in the viewing glass via the water drain plug -6-.

-- Open the valve -3-.

CAUTION:

Risk of damaging the components if the pressure is set too high.

- Never set the test pressure above the specified adjustment.

-- Set the pressure to 0.2 bar (2.9 psi) using the pressure regulating valve -2-.

-- Open the valve -4- and wait until the test circuit is filled. Regulate the pressure to 0.2 bar (2.9 psi) again if necessary.

-- Open the cap on the oil filler tube.

-- Check the charge air circuit for leaking areas:

By listening, also on the oil filler tube
By feeling
With a commercially available leak detection spray
With the Ultrasonic Tester :V.A.G 1842S . Refer to the Operating Instructions for the handling.

TIP:

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

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 - CHARGE AIR HOSE CONNECTIONS