Charge Air System, Checking For Leaks

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Special tools and workshop equipment required

Testing Unit for Turbocharger V.A.G 1687 with Adapter V.A.G 1687/12

Procedure

-- Remove the engine cover. Refer to ENGINE COVER .

-- Press the release buttons and remove the crankshaft housing ventilation hose -1- from the cylinder head cover.

Fig 1: Identifying Crankcase Ventilation Hose And Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Disconnect the connector from the crankcase ventilation hose -1-.

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

-- Loosen the hose clamps -3- and remove the air guide pipe from the air filter housing.

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

-- Remove the bolts -arrows-.

Fig 2: Identifying Pulsation Damper, Removal

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the hose clamps -1- and remove the pulsation damper -2-.

-- Install the Adapter 1687/12 into the intake hose -1- and secure it with a clamp.

Fig 3: Identifying V.A.G 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Prepare the Turbocharger Testing Unit V.A.G 1687 as follows:

-- Fully turn out the pressure regulator valve -2- to the closed position and close the valves -3- and -4-.

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Pull the knob in order to rotate the pressure regulating valve -2-.

-- Connect the Testing Unit for Turbocharger V.A.G 1687 as shown, to the Adapter 1687/12.

Fig 5: Identifying V.A.G 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Connect the pressurized air hose -1- (pressurized air supply) to the Testing Unit for Turbocharger V.A.G 1687.

Fig 6: Connecting Pressurized Air Hose To Testing Unit For Turbo Charger V.A.G 1687

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

-- Open the valve -3-.

-- Set the pressure to 0.5 bar using the pressure control 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 test circuit is filled. Adjust the pressure to 0.5 bar if necessary.

-- Check the charge air system for leaks by/with:

Listening
Touching
Commercially available leak spray
Ultrasonic Measuring Device V.A.G 1842

NOTE:

Small leaks on the intake side of the turbocharger or permitted because the intake hoses are not designed for positive pressure.

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

Handling instructions of Ultrasonic Measuring Device V.A.G 1842. Refer to Owner's Manual.

If a poorly sealed area is discovered, observe the notes for charge air system when repairing.

Before removing adapter, discharge pressure in testing circuit by pulling off coupling from Adapter 1687/10.

Assembling

Assembly is performed in reverse order. Note the following:

NOTE:

Replace the gasket and O-ring.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure the hose connections with standard production clamps. Refer to the Parts Catalog.

-- Install the intake tube and pulsation damper, refer to TURBOCHARGER OVERVIEW .

-- Install the air duct hoses and screw-type clamps CHARGE AIR HOSE CONNECTIONS .