Checking charge air system for leaks

Special tools and workshop equipment required

• Charge air system tester - V.A.G 1687- with adapter - V.A.G 1687/10- and adapter - V.A.G 1687/14-

• Hose clamp pliers - VAS 6340-
• Engine bung set - VAS 6122- (not shown)

• Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.
• Press hose locking mechanism and pull hose for crankcase breather -1- off intake connecting pipe.
• Also pull crankcase breather hose off valve timing housing.

• Seal intake connecting pipe with a bung from engine bung set - VAS 6122-.
• Slacken spring-type clips -2- from intake hose and remove intake hose.

• Renew spring-type clips -arrows- with screw-type clips from charge air system tester - V.A.G 1687-.
• Slide the adapter - V.A.G 1687/14- onto the intake connecting pipe and secure the hose with the relevant screw-type clip.

• Slide the adapter - V.A.G 1687/10- into the adapter - V.A.G 1687/14- and secure the adapter with the screw-type clip.
• Connect hose -1- to the charge air system tester - V.A.G 1687-.

Prepare charge air system tester - V.A.G 1687- as follows:

• Unscrew pressure regulating valve -2- and close valves -3- and -4-.

• Connect pressure hose -1- (compressed air supply) to charge air system tester - V.A.G 1687-.

• Open valve -3-.
• Adjust pressure to 0.5 bar with pressure regulating valve -2-.

• Open valve -4- and wait until the test circuit is filled. If necessary readjust pressure to 0.5 bar.
• Check the charge air system for leaks by hearing, touching, with commercially available leak detector spray or using ultrasonic tester - V.A.G 1842-.

• Push engine cover panel down at points -1- in direction of -arrow- until it engages.