Turbocharger: Testing and Inspection

Charge Air System, Checking for Leaks

Special tools, testers and auxiliary items required

• Testing Unit for Turbocharger (V.A.G 1687)

• End Seal (V.A.G 1687/5)

- Remove the noise insulation.

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

- Install the end seal (V.A.G 1687/5) to charge air hose - A - and rotate it approximately 90° - B -.

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

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

- Close the valves - 3 and 4 -.

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

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

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

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

- Open the valve - 3 -.

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

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

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

- Check the charge air system for leaks by listening, feeling, using commercially available leak detection spray or by using the ultrasonic measuring device (V.A.G 1842).

• Charge air hose connecting, refer to => [ Charge Air Hose, Disconnecting and Connecting ] Charge Air Hose, Disconnecting and Connecting.

• A small quantity of air dissipates via the 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 the operator's manual.

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

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