Charge Air Cooler, Checking For Leaks

Special tools and workshop equipment required

Turbo System Tester Kit :VAG1687

Fig 1: Identifying Turbo System Tester Kit
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Turbo System Tester Kit - Adapter 10 :VAG1687/10
Turbo System Tester Kit - Adapter :VAG1687/13-2
Engine Bung Set :VAS6122

Fig 2: Engine Bung Set
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Cooling System Tester - Directional Valve :VAS691005/1

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Cooling System Tester - Directional Valve :VAS691005/5
Digital Pressure Sensor :VAG1397B

Fig 3: Identifying Turbocharger Tester V.A.G 1397 A
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Test Conditions:

Coolant temperature must be at least 40 °C (104 °F).

Turbocharger Tester Kit :VAG1397A , Connecting:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Attach the Cooling System Tester - Directional Valve :VAS691005/5 to the coolant expansion tank.

-- Attach the Cooling System Tester - Directional Valve :VAS691005/1 to the Cooling System Tester - Directional Valve :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 Turbocharger Tester Kit : VAG1397A .

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

Turbo System Tester Kit :VAG1687 , Connecting:

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the breather line -3-. To do so press the locking mechanism.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Then seal the open connection on the breather line using suitable plugs from the Engine Bung Set :VAS6122 .

-- Loosen the hose clamps -arrows- on the connection -1- on the air filter housing -2-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the air duct hose -3-.

-- Connect the Turbo System Tester Kit - Adapter 15 :VAG1687/15 -A- with the Turbo System Tester Kit - Adapter 11 :VAG1687/11 -B- to the turbocharger -1-.

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Check if the open connections -arrows- are sealed with suitable plugs from the Engine Bung Set :VAS6122 -D-.

2 - Breather Line on the Crankcase Ventilation

3 - Intake Manifold

-- Connect the hose -C- from the Turbo System Tester Kit :VAG1687 to the adapter.

Prepare the Turbo System Tester Kit :VAG1687 as follows:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pull the pressure regulating valve -2- upward and remove completely, close the valves -3 and 4-.

-- Connect the Turbo System Tester Kit :VAG1687 to compressed air -1- with a commercially available intermediate piece.

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

-- Open the valve -3-.

-- Set the pressure to 0.5 bar (7.25 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 (7.25 psi) again if necessary.

NOTE:

A small amount of air escapes via the valves in the engine and the exhaust system. For this reason a pressure retention test is not possible.

Turbocharger Tester Kit :VAG1397A , Reading:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Watch the Turbocharger Tester Kit for approximately five minutes.
The pressure displayed on the Turbocharger Tester Kit must not increase above 0.025 bar (0.36 psi).

-- If the pressure continues to increase above 0.025 bar (0.36 psi) on the Turbocharger Tester Kit, compressed air is leaking from the intake side in the cooling system. If the charge air cooler is leaking replace it.

NOTE:

Depending on the subsequent heating of the coolant (post-heating effect), a lower pressure increase of 0.025 bar (0.36 psi) can occur. This low pressure increase does not indicate a leak.

A vacuum can occur when cooling the coolant. The vacuum is displayed on the Turbocharger Tester using a >>negative<< symbol. Values with a >>minus<< do not indicate a leak.

Repeat the test if there is any uncertainty. To do this, open the shut-off valve -1- briefly and balance the pressure in the cooling system. If the charge air cooler is leaking, the pressure must continue to increase during every test.

Cooling System Tester - Directional Valve :VAS691005/1 , Cleaning:

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

After completing the leak test, the Cooling System Tester - Directional Valve :VAS691005/1 must be cleaned to remove any entrapped moisture.

-- Insert the cleaning nozzle -D- in the hose from connection -A- on the Directional Valve.

-- Connect the Cooling System Tester - Directional Valve :VAS691005/5 on the hose from the connector -B-.

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

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

Assemble in the reverse order of removal. Note the following:

-- Replace the O-rings.

Refer to OVERVIEW - AIR FILTER HOUSING
Refer to OVERVIEW - CRANKCASE VENTILATION
Refer to OVERVIEW - INTAKE MANIFOLD