EGR Cooler, Checking For Leaks

WARNING: This page is about a different variant/trim than selected.

Special Tools And Workshop Equipment Required

Turbo System Tester Kit :VVAG1687
Turbo System Tester Kit - Adapter 11 :VVAG1687/11
Turbo System Tester Kit - Adapter 15 :VVAG1687/15 for 60 mm and 65 mm diameter exhaust pipes
Turbo System Tester Kit - Adapter 16 :VVAG1687/16 for 55 mm diameter exhaust pipe
Cooling System Tester - Directional Valve :VAS69005/1
Cooling System Tester - Directional Valve :VAS691005/5
Digital Pressure Sensor :VAG1397B

Turbocharger Tester Kit :VAG1397A , Connecting

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-- Attach the :VAS691005/5 to the coolant expansion tank.

-- Attach the :VAS69005/1 to the :VAS691005/5 .

-- Connect the valve -1- for connection >>C<< and open the valve -2- for connection >>A<<.

-- Connect the hose from connection >>A<< from the :VAS69005/1 to the connection >>II<< on the : VAG1397A .

-- Set the : VAG1397A to switch setting >>II<< (relative pressure measurement) and turn it on. The >>II<< must be visible.

Turbo System Tester Kit :VVAG1687 , Connecting

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-- If equipped, remove the connector -1- from the exhaust door control unit.

-- Loosen the clamping sleeve -2- on the exhaust pipe and slide it toward the rear.

-- Connect the :VVAG1687/11 with the hose -A- to the exhaust pipe (engine-side). Secure the hose with hose clamps.

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Use the hose -A- for the exhaust pipes with 55 mm diameter = :VVAG1687/16 .

Use the hose -A- for the exhaust pipes with 60 mm or 65 mm diameter = :VVAG1687/15 .

-- Connect the :VVAG1687 to the :VVAG1687/11 .

Prepare the :VVAG1687 as follows:

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-- Completely remove the pressure regulating valve -2- and close the valves -3 and 4-.

The knob must be pulled upward so that the pressure regulating valve -2- can be turned.

-- Connect the :VVAG1687 to the compressed air -1-.

-- If there is water in the viewing glass, drain it through the drain plug -6-.

-- Open the valve -3-.

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-- Set the pressure to 0.5 bar (7.2 psi) using the pressure regulating valve -2-.

-- Open the valve -4- and wait until the test circuit is filled. Regulate the pressure to 0.5 bar (7.2 psi) again if necessary.

NOTE:

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

Turbocharger Tester Kit :VAG1397A , Reading:

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Watch the :VAG1397A for approximately five minutes.
The pressure displayed on the :VAG1397A must not increase.

-- If the pressure increases on the :VAG1397A , compressed air is leaking from the exhaust side in the cooling system. The EGR cooler is leaking. Replace the EGR cooler.

Cooling System Tester - Directional Valve :VAS69005/1 , Cleaning

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NOTE:

After completing the leak test, the :VAS69005/1 must be cleaned to remove any entrapped moisture.

-- Insert the cleaning nozzle -D- in the hose from connection -A- on the :VAS69005/1 .

-- Connect the pressure hose to the connection -C-.

-- Open the shut-off valves and blow through the hose for approximately 15 seconds.