EGR Cooler, Checking For Leaks

WARNING: This page is about a different car, the 2015 Volkswagen Golf. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Turbo System Tester Kit:VAG1687
Turbo System Tester Kit - Adapter 11:VAG1687/11
Turbo System Tester Kit - Adapter 15:VAG1687/15 for exhaust pipes 60 mm and 65 mm diameter
Turbo System Tester Kit - Adapter 16:VAG1687/16 for exhaust pipe 55 mm diameter
Cooling System Tester - Directional Valve:VAS691005/1
Cooling System Tester - Directional Valve:VAS691005/5
Turbocharger Tester Kit:VAG1397A

:VAG1397A , Connecting:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Attach the :VAS691005/1 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 Directional Valve 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.

:VAG1687 , Connecting:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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 :VAG1687/11 with hose -A- on the exhaust pipe (engine-side). Secure the hose with hose clamps.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Use the hose -A- for the exhaust pipes with 55 mm diameter = :VAG1687/16 .

Use the hose -A- for the exhaust pipes with 60 mm or 65 mm diameter = :VAG1687/15 .

-- Connect the :VAG1687 to :VAG1687/11

Prepare the :VAG1687 as follows:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Connect the :VAG1687 to the compressed air -1-.

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

-- Open the valve -3-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- 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.

:VAG1397A , Reading:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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.

:VAS691005/1 , Cleaning:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

After completing the leak test, the :VAS691005/1 must be cleaned to remove any entrapped moisture.

-- Insert the cleaning nozzle -D- in the hose from connection -A- on the Y distribution piece.

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

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