Charge Air System, Checking For Leaks

Charge Air System, Checking for Leaks

Special tools, testers and auxiliary items required

• Turbocharger testing unit (V.A.G 1687)





• Adapter (V.A.G 1687/5)

- Remove noise insulation.

- Release securing clip - A - and disconnect hose - B - from charge air pipe.





- Connect adapter (V.A.G 1687/5) to charge air hose - A - and rotate it around approximately 90° - B -.





Prepare testing unit for turbocharger (V.A.G 1687) as follows:

- Turn the pressure regulating valve - 2 - counterclockwise until it stops.





- Close the valves - 3 - and - 4 -.

• In order to be able to turn pressure regulator valve - 2 -, rotary knob must be pulled upward.

- Connect testing unit for turbocharger (V.A.G 1687) as shown.





- Connect pressurized air hose - 1 - (pressurized air supply) to testing unit for turbocharger (V.A.G 1687).





• If water is located in viewing glass, drain it via water drain plug - 6 -.

- Open valve - 3 -.

- Set pressure to 0.5 bar using pressure regulator valve - 2 -.

CAUTION!
Pressure must not exceed 0.5 bar! A pressure set too high may damage the engine.

- Open valve - 4 - and wait until testing circuit has filled. If necessary, continue to regulate pressure to 0.5 bar.

- Check charge air system for leaking areas by listening, touch, using leak detection spray or using ultrasonic measuring device (V.A.G 1842).

• Assembly of hose connections with connection couplings => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections With Connector Couplings, Assembling

• 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) => Owner's Manual.

• Before removing adapter, discharge pressure in testing circuit by pulling off coupling from adapter (V.A.G 1687/5).

• Hose connections and charge air system hoses must be free of oil and grease before installing.