Charge Air System, Checking For Leaks

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 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 VAG 1687
Adapter VAG 1687/5
Ultrasonic measuring device VAG 1842

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

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

Fig 1: Identifying Locking Clip & Charge Air Hose

GWWN21-10041

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the VAG 1687/5 to the charge air hose -A- and rotate it approximately 90 degrees -B-.

Fig 2: Connecting Adapter V.A.G 1687/5 To Charge Air Hose And Rotate It Around Approx. 90Degrees

GWWN21-10039

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Prepare the VAG 1687 as follows:

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

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

GWWV21-0168

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

-- Connect the VAG 1687 as shown.

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

GWWN21-10040

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect a compressed air hose -1- (pressurized air supply) to the VAG 1687.

Fig 5: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

GWWV21-0168

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 testing circuit has filled. If necessary, continue to regulate pressure to 0.5 bar.

-- Check the charge air system for leaks by listening, touching, using leak detection spray or using the VAG 1842.

NOTE:

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

Before removing the VAG 1687/5, discharge the pressure in the testing circuit by disconnecting the compressed air hose from the VAG 1687/5.

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