Charge Air System, Checking For Leaks

WARNING: This page is about a different car, the 2006 Volkswagen Jetta and 2005 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Turbocharger testing unit V.A.G 1687
Accessory adapter V.A.G 1687/1

-- Remove intake hose -1- from air filter.

Fig 1: Identifying Turbocharger Testing Unit V.A.G 1687 Connected To Accessory Adapter V.A.G 1687/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place adapter V.A.G 1687/1 in intake hose -1- and secure it with a clamp.

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

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

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

-- Connect the testing unit for turbocharger V.A.G 1687 on adapter V.A.G 1687/1 as shown.

Fig 3: Identifying Turbocharger Testing Unit V.A.G 1687 Connected To Accessory Adapter V.A.G 1687/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Identifying Pressurized Air Hose Connected To Testing Unit For Turbo Charger V.A.G 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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:

Using the ultrasonic measuring device V.A.G 1842. See relevant operating instructions.

If a poorly sealed area is discovered, observe the notes for charge air system when repairing TURBOCHARGER ASSEMBLY OVERVIEW .

Before removing the adapter, release pressure from the test circuit by separating the connection from the accessory adapter V.A.G 1687/1.