Charge Air System, Checking For Leaks

WARNING: This page is about a different car, the 2010 Volkswagen Jetta, 2009 Volkswagen Jetta, 2009 Volkswagen GLI, 2008 Volkswagen Jetta, and 2008 Volkswagen GLI. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Adapter V.A.G 1687/5
Testing Unit for Turbocharger V.A.G 1687
Ultrasonic Measuring Device V.A.G 1842

Test Sequence:

-- Remove the noise insulation. Refer to Description and Operation .

-- Release the securing clamp -A- and disconnect the hose -B- from the charge air pipe.

Fig 1: Identifying Locking Clip & Charge Air Hose

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-- Connect the adapter V.A.G 1687/5 to the charge air hose -A- and rotate it around approximately 90° -B-.

Fig 2: Identifying Method To Connect Adapter V.A.G 1687/5 To Charge Air Hose

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

Fig 3: Identifying Pressurized Air Hose Connected To Testing Unit For Turbo Charger V.A.G 1687

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-- Turn the pressure regulator valve -2- counterclockwise until it stops.

-- Close the valves -3 and 4-.

NOTE:

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

-- Connect the testing unit for turbocharger V.A.G 1687 as shown.

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

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

Fig 5: 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 the viewing glass, drain it via water the drain plug -6-.

-- Open the valve -3-.

-- Set the pressure to 0.5 bar using pressure the regulator valve -2-.

CAUTION:

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

-- Open the valve -4- and wait until the testing circuit has filled. If necessary, continue to regulate pressure to 0.5 bar.

-- Check the charge air system for poorly sealed areas by listening, feeling, using commercially available leak detection spray or by using the ultrasonic measuring device V.A.G 1842.

NOTE:

Charge air hose connecting and disconnecting, Refer to CHARGE AIR HOSE AND PIPE, DISCONNECTING AND CONNECTING .

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

Handling instructions for the ultrasonic measuring device V.A.G 1842. Refer to the tools operating instructions.

Before removing the adapter, discharge the pressure in the testing circuit by pulling off the coupling from the adapter V.A.G 1687/5.

Hose connections and charge air system hoses must be free of oil and grease before installing.