Checking charge air system for leaks

Special tools and workshop equipment required

• Charge air system tester - V.A.G 1687-

Procedure

• Remove resonator for intake air ⇒ 3.3 Removing and installing resonator for intake air.

• Press release tabs, and disconnect hose -1- for activated charcoal filter.

• Cover coolant pump with a cloth to collect any escaping oil.
• Seal open connection of turbocharger using a suitable plug from engine bung set - VAS 6122-.

• Connect adapter - V.A.G 1687/15- with adapter -V.A.G 1687/11- to turbocharger.
• Connect hose -1- of charge air system tester -V.A.G 1687- to adapter.

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

• Completely unscrew pressure regulating valve -2-, close valves -3- and -4-.

• To turn the pressure regulating valve -2- the knob must be pulled upwards.

• Connect charge air system tester - V.A.G 1687- to compressed air -1- via commercial adapter.

• Open valve -3-.

Risk of damage to engine

Risk of damage because pressure is set too high.

The pressure must not exceed 0.5 bar.

• Adjust pressure to 0.5 bar with pressure control valve -2-.
• Open valve -4- and wait until test circuit is full. If necessary, adjust pressure to 0.5 bar.
• Check charge air system for leaks by hearing, touching, with commercially available leak detector spray or using ultrasonic tester - V.A.G 1842-.

Installing

Assemble in reverse order of dismantling. The following should be observed: