Charge Air System, Checking For Leaks

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. 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 with Turbo System Tester Kit - Adapter 12 VAG1687/12
Hose Clip PliersVAS6362

Procedure

-- Remove the engine cover, refer to ENGINE COVER .

-- If equipped remove the vacuum hose -arrow-.

Fig 1: Identifying Vacuum Hose

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the hose -1- for the crankcase ventilation on the air guide hose.

Fig 2: Identifying Release Buttons

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- To do this press the release button.

CAUTION:

Depending on the vehicle equipment level and market-specific crankcase ventilation hose may be used, which cannot be removed from the cylinder head cover without being destroyed. For these version the crankcase ventilation hose can only be separated at the air guide hose connection.

-- Release the connector from the air guide hose and remove.

-- Unclip the wires on the intake tube.

-- Free up the vacuum hoses -arrows- on the air guide pipe.

-- Remove bolt -2- and tilt the air guide hose with the intake tube backward and remove from the turbocharger.

-- Connect the Turbo System Tester Kit - Adapter 11VAG1687/11 with the VAG1687/15 to the turbocharger.

Fig 3: Identifying Turbo System Tester Kit - Adapter 11

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the Turbo System Tester KitVAG1687 to the adapter.

Prepare the Turbo System Tester KitVAG1687 as follows:

Fig 4: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

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

-- Connect the Turbo System Tester KitVAG1687 to compressed air -1- with a commercially available adapter piece.

NOTE:

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

-- Open the valve -3-.

CAUTION:

Damage could result if the pressure is set too high.

Pressure must not exceed 0.5 bar (7.2 psi)!

-- Set the pressure to 0.5 bar (7.2 psi) using the pressure control 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.

-- Check the charge air system for leaking areas.

By listening and feeling
With a commercially available leak detection spray
With the Ultrasonic Tester VAG1842SVAG1842S

NOTE:

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

For information on using the Ultrasonic Tester VAG1842S, refer to the Owner's Manual.

Release the pressure in the test circuit by pulling off the hose coupling before removing the adapter.

Assembling

Assembly is performed in reverse order.

Tightening specification, refer to OVERVIEW - AIR FILTER HOUSING