Charge Air System, Checking For Leaks

WARNING: This page is about a different car, the 2009 Volkswagen GTI and 2008 Volkswagen GTI. 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-
Adapter -V.A.G 1687/5-

-- 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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- 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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Connect a pressurized air hose -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 UNITED STATES, 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 testing circuit has filled. If necessary, continue to regulate the pressure to 0.5 bar.

-- 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 hose, installing. Refer to CHARGE AIR HOSE, INSTALLING .

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

Handling instructions of ultrasonic measuring device -V.A.G 1842-. Refer to the user's manual.

Before removing the adapter, discharge 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.