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Exhaust system > < Removing and installing charge air cooler

A1

Checking charge air system for leaks
Checking charge air system for leaks
Special tools and workshop equipment required
   
t  Charge air system tester -V.A.G 1687- with adapters -V.A.G 1687/11- and -V.A.G 1687/16-
  W00-10327
Procedure
–  Remove engine cover panel -arrows-.
  A10-11183
–  Press release tabs and disconnect crankcase breather hose -1-.
–  Release hose clips -2 and 3- and remove air hose.
  A21-10691
–  Connect adapter -V.A.G 1687/11- with -V.A.G 1687/16- to turbocharger.
–  Connect hose -1- of charge air system tester -V.A.G 1687- to adapter.
  A21-10629
Prepare charge air system tester -V.A.G 1687- as follows:
–  Unscrew pressure control valve -2- completely and close valves -3- and -4-.
l  Make sure knob is pulled out before turning pressure control valve -2-.
–  Using a commercially available connection piece, connect charge air system tester -V.A.G 1687- to compressed air -1-.
  Note
If there is water in sight glass, remove drain plug -6- and drain water.
–  Open valve -3-.
  Caution
Risk of damage if pressure is set too high.
The pressure must not exceed 0.5 bar.
–  Adjust pressure to 0.5 bar via pressure control valve -2-.
–  Open valve -4- and wait until test system is pressurised. If necessary, adjust pressure to 0.5 bar again.
–  Check charge air system for audible leaks or leaks that can be felt with the hand; apply commercially available leak detecting spray or use ultrasonic tester -V.A.G 1842-.
  Note
t  A small amount of air escapes through the valves and enters the engine. Therefore it is not possible to perform a pressure retention test.
t  For operation of ultrasonic tester -V.A.G 1842-, refer to → Operating instructions.
t  Release pressure in test circuit by detaching hose coupling from adapter before removing adapter.
Assembling
Installation is carried out in the reverse order; note the following:
l  Tightening torques → Chapter „Turbocharger - exploded view“
  Note
Renew gasket and O-rings.
  V21-0168

Exhaust system > < Removing and installing charge air cooler