Intercooler: Testing and Inspection

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 1687/5

- 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 approx. 90 degrees -B-.

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







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

NOTE: 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.

NOTE: If water is located in viewing glass, drain it via water drain screw -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.

NOTE:
- Assembly of hose connections with connection couplings.
- A small quantity of air dissipates via valves in engine. A retaining pressure test is not possible for this reason.
- Handling instructions of ultrasonic measuring device V.A.G 1842 Owners 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.