Component Tests and General Diagnostics

Charge Air System, Checking for Leaks

Special tools, testers and auxiliary items required

• Adapter (V.A.G 1687/12)

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

Procedure

- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.

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






- Disconnect the connector and remove it from the crankcase ventilation hose - 1 -.

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

- Loosen the hose clamps - 3 - and remove the air guide pipe from the air filter housing.

- Remove the bolt - 2 - and turn the air guide pipe with the intake hose toward the back and remove from the turbocharger.

- Remove the bolt - arrow -.






- Unclip the preheating pipe - 1 - and remove it from the bracket.

- Remove the bolts - arrows -.






- Loosen the hose clamps - 1 - and remove the pulsation damper - 2 -.

- Install the adapter (1687/12) into the intake hose - 1 - and secure it with a clamp.






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

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






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

- Connect the testing unit for turbocharger (V.A.G 1687) as shown, to the adapter (1687/12).






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






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

- Open the valve - 3 -.

- Set the pressure to 0.5 bar using the pressure control 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 test circuit is filled. Adjust the pressure to 0.5 bar if necessary.

- Inspect the entire charge air system.

Test methods:

• Listening

• Touching

• Commercially available leak spray

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

• Small leaks on the intake side of the turbocharger or 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.

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

• If a poorly sealed area is discovered, observe the notes for charge air system when repairing.

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

Assembling

Assembly is performed in reverse order. When doing this note the following:

• Replace the gasket 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 hose connections with standard production clamps. Refer to the Parts Catalog.

- Install the intake tube and pulsation damper. Refer to => [ Turbocharger and Attachments Overview ] Turbocharger and Attachments Overview.

- Install the charge air hoses and screw type clamps. Refer to => [ Charge Air Pipe/Hose, Connecting ] Service and Repair.