Charge Air System, Checking For Leaks

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

Special tools and workshop equipment required

Testing Unit for Turbocharger V.A.G 1687 with Adapter V.A.G 1687/10
Ultrasonic Measuring Device V.A.G 1842, commercially available leak detection spray

CAUTION:

Follow the safety precautions when working on the charge air system and turbocharger. Refer to SAFETY PRECAUTIONS .
Observe the rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Always follow these instructions before and during work.

Test Sequence

-- Disconnect the intake tube -1- from the mass airflow sensor -G70-. Loosen the hose clamps using hose clip pliers VAS 6362.

Fig 1: Identifying Adapter VAG1687/10 In Intake Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Place the adapter V.A.G 1687/10 in the intake tube -1- and secure it with a clamp.

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

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

Fig 2: Connecting Pressurized Air Hose 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 the pressure regulator valve -2-, the rotary knob must be pulled upward.

-- Connect the testing unit for turbocharger V.A.G 1687 to the adapter V.A.G 1687/10 as shown.

Fig 3: Identifying Adapter VAG1687/10 In Intake Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Connecting Pressurized Air Hose 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 the water drain plug -6-.

-- Open the valve -3-.

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

CAUTION:

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

-- Open the valve -4- and wait until the test circuit is filled. Adjust the pressure to 0.5 bar if necessary.

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

NOTE:

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

Small leaks on the intake side of the turbocharger are permitted because the intake hoses are not designed for positive pressure.

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

For handling instructions of the ultrasonic measuring device V.A.G 1842. Refer to the tools owners manual.

If a poorly sealed area is discovered, observe the notes for the charge air system when repairing. Refer to CHARGE AIR SYSTEM .

Before removing the adapter, discharge the pressure in the testing circuit by pulling off the hose from the adapter V.A.G 1687/10.