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Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC > < Removing and installing charge air cooler, engines with code letters AXX, BPY, BWA

A3 Mk2

Checking charge air system for leaks, engines with code letters AXX, BPY, BWA
Checking charge air system for leaks, engines with code letters AXX, BPY, BWA
Special tools and workshop equipment required
   
t  Charge air system tester -V.A.G 1687-
t  Adapter -V.A.G 1687/5-
–  Remove noise insulation tray → General body repairs, exterior; Rep. gr.50.
  W00-10327
–  Release clip -A- and detach hose -B- from charge air pipe.
  N21-10041
–  Fit adapter -V.A.G 1687/5- onto charge air hose -A- and turn adapter through approx. 90° -B-.
Prepare charge air system tester -V.A.G 1687- as follows:
  N21-10039
–  Unscrew pressure control valve -2- all the way and close valves -3- and -4-.
  Note
Make sure knob is pulled out before turning pressure control valve -2-.
  V21-0168
–  Connect charge air system tester -V.A.G 1687- as illustrated.
  N21-10040
–  Connect pressure hose -1- (compressed air supply line) to charge air system tester -V.A.G 1687-.
  Note
If sight glass contains water, loosen drain plug and drain water -6-.
–  Open valve -3-.
–  Adjust pressure to 0.5 bar via pressure control valve -2-.
  Caution
The pressure must not exceed 0.5 bar. If the pressure is set too high this can damage the engine.
–  Open valve -4- and wait until test system is pressurised. Re-adjust pressure to 0.5 bar if necessary.
–  Check charge air system for visible or audible leaks and 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  Operation of ultrasonic tester -V.A.G 1842- → Operating instructions.
t  Release pressure by detaching coupling from adapter -V.A.G 1687/5- before removing adapter.
t  Hose connections and hoses for charge air system must be free of oil and grease before assembly.
–  Install air pipes with plug-in connectors → Chapter.
  V21-0168

Turbocharger with charge air system, engines with code letters BHZ, BZC, CDLA, CDLC > < Removing and installing charge air cooler, engines with code letters AXX, BPY, BWA