Charge Air System, Checking For Leaks

Charge Air System, Checking for Leaks

Special tools, testers and auxiliary items required

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

• Adapter (V.A.G 1687/10)

- Remove the intake hose - 1 - from the air filter housing.






- Install the adapter (1687/10) into the intake hose - 1 - and secure it with a clamp.

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

- Unscrew the pressure regulator valve - 2 - completely and close valves - 3 and 4 -.






• Pull the knob up in order to rotate the pressure regulator valve - 2 -.

- Connect the testing unit for turbocharger (V.A.G 1687) to the adapter (1687/10) 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 -.


The 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 the pressure to 0.5 bar.

- Check for leaks in the charge air system using/by:

• Listening

• Touching

• Commercially available leak spray

• ultrasonic measuring device (V.A.G 1842)

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

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

• Handling instructions of the ultrasonic measuring device (V.A.G 1842). Refer to the operators manual.

• If a poorly sealed area is discovered, observe the notes for the charge air system when repairing. Refer to => [ Charge Air System Components Overview ] Service and Repair.

• Before removing the adapter, discharge the pressure in the testing circuit by pulling off the coupling from the adapter (1687/10).