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) with Adapter (V.A.G 1687/12)

Procedure

- Remove the engine cover - arrows -.





- Press the release buttons and remove the crankshaft housing ventilation hose - 1 - from the cylinder head cover.





- Free up the vacuum hoses - arrows - on the air guide pipe.

- Loosen clamps - 2 - and - 3 - and remove the air guide pipe.

- Remove bolts - arrows -.





- Loosen hose clamp - 1 - and remove the pulsation damper.

- Install the (V.A.G 1687/12) into the air guide hose - 1 - and secure it with a clamp.





- Connect the (V.A.G 1687) to the adapter.

Prepare the (V.A.G 1687) as follows:

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





• The rotary knob must face upward so the pressure control valve - 2 - can be turned.

- Connect the (V.A.G 1687) to compressed air - 1 - with a commercially available adapter piece.

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

- Open the valve - 3 -.


Damage could result if the pressure is set too high.

• Pressure must not exceed 0.5 bar!

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

- Open the valve - 4 - and wait until the test circuit is filled. Regulate the pressure to 0.5 bar again if necessary.

- Listen, feel and use commercially available leak detection spray or the ultrasonic tester (V.A.G 1842) to check the charge air system for leaks.

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

• For information on using the (V.A.G 1842), refer to the => Operating Instructions.

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

Assembling

Assembly is in reverse order of removal, note the following:

• Replace the seal and O-ring.

• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

• Secure all hose connections with hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.

• In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

- Install the pulsation damper. Refer to => [ Turbocharger Assembly Overview ] Turbocharger Assembly Overview.