Charge Air System, Checking For Leaks

Special tools and workshop equipment required

Turbo System Tester Kit :VAG1687

Fig 1: Identifying Turbo System Tester Kit
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Turbo System Tester Kit - Adapter 10 :VAG1687/10

Fig 2: Identifying Turbo System Tester Kit
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Adapter :VAG1687/20
Turbo System Tester Kit - Adapter :VAG1687/13-2
Engine Bung Set :VAS6122

Fig 3: Engine Bung Set
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Procedure

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

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

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-- 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-.

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-- Remove the air duct hose -3-.

-- Release and detach the breather line -4-.

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-- Then seal the open connection on the intake tube on the turbocharger -1- using suitable plugs from the Engine Bung Set :VAS6122 -A-.

-- Connect the Turbo System Tester Kit - Adapter 20 :VAG1687/20 -A- with the Turbo System Tester Kit - Adapter 11 :VAG1687/11 -B- to the turbocharger -1-.

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-- 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:

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-- 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.

-- Check the charge air system for leaking areas:

By listening
By feeling
With a commercially available leak detection spray
With the Ultrasonic Tester VAG1842S :VAG1842S

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.

Refer to the Operating Instructions for information on using the Ultrasonic Tester :VAG1842S .

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

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