Charge Air System, Checking For Leaks: Procedure

:VAG1397A  , Connecting:

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Attach the :VAS691005/5  to the coolant expansion tank.

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-- Attach the :VAS691005/1  to the :VAS691005/5  .

-- Connect the valve -1- for connection >>C<< and open the valve -2- for connection >>A<<.

-- Connect the hose from connection >>A<< from the Directional Valve to the connection >>II<< on the : VAG1397A  .

-- Set the : VAG1397A  to switch setting >>II<< (relative pressure measurement) and turn it on. The >>II<< must be visible.

:VAG1687  , Connecting:

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-- Free up the vacuum hoses -arrows-.

-- Loosen the hose clamps -1 and 2- and remove the air duct pipe.

-- Remove the vent pipe for the crankcase ventilation -arrow-.

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-- Seal the connections with suitable plugs -1- from the :VAS6122  . Secure the plug with a hose clamp -2-.

-- Connect the :VAG1687/11  with the :VAG1687/15  to the turbocharger.

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-- Connect the :VAG1687  to the adapter.

Prepare the :VAG1687  as Follows:

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-- Pull the pressure regulating valve -2- upward and remove completely, close the valves -3 and 4-.

-- Connect the :VAG1687  to compressed air -1- with a commercially available intermediate piece.

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

-- Open the valve -3-.

-- Set the pressure to 0.5 bar (7.2 psi) using the pressure regulating valve -2-.

-- Open the valve -4- and wait until the test circuit is filled. Regulate the pressure to 0.5 bar (7.2 psi) again if required.

• A small quantity of air dissipates via valves in engine and the EGR cooler. For this reason a pressure retention test is not possible.
• Refer to the Owner's Manual for information on using the :VAG1842S  .

-- Check the charge air circuit for leaking areas:

• By listening
• By feeling
• By commercially available leak detection spray
• With the :VAG1842S 

If no leaks are found in the charge air circuit, check the water-cooled charge air cooler for leaks.

Turbocharger Tester Kit:VAG1397A  , Reading:

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-- The pressure must be set to 0.5 bar (7.2 psi) at the same time.

• Watch the :VAG1397A  for approximately five minutes.
• The pressure displayed on the :VAG1397A  must not increase.

-- If the pressure increases on the :VAG1397A  , compressed air is leaking in the cooling system.

-- The charge air cooler is leaking replace the intake manifold with charge air cooler.

• By cooling the coolant, a vacuum can result on a sealed charge air cooler. The vacuum is displayed on the :VAG1397A  using a >>negative<< symbol.

Cooling System Tester - Directional Valve:VAS691005/1  , Cleaning:

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• After completing the leak test, the :VAS691005/1  must be cleaned to remove any entrapped moisture.

-- Insert the cleaning nozzle -D- in the hose from connection -A- on the :VAS691005/1  .

-- Connect the :VAS691005/5  on the hose from the connector -B-.

-- Connect the pressure hose to the connection -C-.

-- Open the shut-off valves and blow through the hose for approximately 15 seconds.

-- Release the pressure in the test circuit by removing the hose coupling before removing the adapter.