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 1687/10)

• Ultrasonic Measuring Device (V.A.G 1842) commercially available leak detection spray

CAUTION!
• Follow the safety precautions when working on the charge air system and turbocharger. Refer to --> [ Safety Precautions ] .

• Observe rules for cleanliness. Refer to --> [ Clean Working Conditions ] .

Always follow these instructions before and during work.

Test Sequence

- Disconnect intake hose - 1 - from the MAF sensor. Loosen the hose clips with hose clip pliers (VAS 6362).





- Place Adapter (V.A.G 1687/10) in intake hose - 1 - and secure it with a clamp.

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

- Remove pressure regulator valve - 2 - completely and close 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 Turbo Charger (V.A.G 1687) on Adapter (V.A.G 1687/10) 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).

• Refer to --> [ Coupling between Charge Air Cooler and Connecting Hose ] .

• 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 valves in engine. A pressure retention test is not possible for this reason.

• Refer to handling instructions of ultrasonic measuring device (V.A.G 1842).

• If a poorly sealed area is discovered, observe the notes for charge air system when repairing. Refer to --> [ Charge Air System ] .

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