Charge air system, checking for leaks

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Special tools, testers and auxiliary items required

Fig 1: Testing Unit For Turbo Charger V.A.G 1687

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Testing unit for turbo charger V.A.G 1687
Accessory adapter V.A.G 1687/1

Remove intake hose from air filter.
Remove crankcase ventilation pressure regulator valve from intake hose.

Fig 2: Accessory Adapter 1687/1 Inserted Into Intake Hose And Connection For Pressure Regulator Valve Sealed Using Adapter V.A.G 1687/4

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert accessory adapter 1687/1 into intake hose and seal connection for pressure regulator valve using adapter V.A.G 1687/4. Tighten hose clamps.

Prepare testing unit for turbo charger V.A.G 1687 as follows:

Fig 3: Pressure Regulator Valve Completely Removed And Locating Valves And V.A.G 1687

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove pressure regulator valve - 2 - completely and close valves - 3 - and - 4 -.

NOTE:

In order to be able to turn pressure regulator valve - 2 - , rotary knob must be pulled upward.

Fig 4: Testing Unit For Turbo Charger V.A.G 1687 Connected

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Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect testing unit for turbo charger V.A.G 1687 as shown.

Fig 5: Pressure Regulator Valve Completely Removed And Locating Valves And V.A.G 1687

GW00000702

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect pressurized air hose - 1 - (pressurized air supply) to testing unit for turbo charger V.A.G 1687.

NOTE:

If water is located in viewing glass, drain it via water drain plug - 6 -.

Open valve - 3 -.
Set pressure to 0.5 bar using pressure regulator valve - 2 -.

CAUTION: Pressure must not exceed 0.5 bar! A pressure set too high may damage the engine.

Open valve - 4 - and wait until testing circuit has filled. If necessary, continue to regulate pressure to 0.5 bar.
Check charge air system for leaking areas by listening, touch, using leak detection spray or using ultrasonic measuring device V.A.G 1842.

NOTE:

A minimal amount of air will escape through the turbocharger into the oil pan. A retaining pressure test is not possible for this reason.
Handling instructions of ultrasonic measuring device V.A.G 1842 Owners Manual.
If a poorly sealed area is discovered, observe the notes for charge air system when repairing refer to Charge air system with turbocharger .
Before removing the adapter, release pressure from the test circuit by separating the connection from the accessory adapter 1687/1.