Volkswagen Workshop Service and Repair Manuals > Golf Mk6 > Power unit | 4-cylinder diesel engine (1.6 l engine, common rail) | Exhaust turbocharger, G-charger | Charge air system

Checking charge air system for leaks

Special tools and workshop equipment required

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

t	Adapter -V.A.G 1687/10-

–	Remove intake hose -1- from air filter.

–	Insert adapter -1687/10- in intake hose -1- and secure with clip.

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

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

Note

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

–	Connect charge air system tester -V.A.G 1687- to adapter -1687/10- as shown.

–	Connect compressed air hose -1- (compressed air source) to charge air system tester -V.A.G 1687-.

Note

If there is water in the sight glass, drain at water drain screw -6-.

–	Open valve -3-.

–	Adjust pressure to 0.5 bar with pressure regulating valve -2-.

Caution

The pressure must not exceed 0.5 bar! If the pressure is too high this can cause damage to the engine.

–	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 as follows:

t	By listening

t	By feeling

t	With leak detector spray

t	or with the ultrasonic tester -V.A.G 1842-.

Note

t	Slight leaks on the intake side of turbocharger are permissible, as the intake hoses are not designed for high-pressure.

t	A small amount of air escapes through the valves and enters the engine. Therefore a holding pressure test is not possible.

t	How to use the ultrasonic tester -V.A.G 1842- → operating instructions

t	Depressurise test circuit by detaching coupling from adapter -1687/10- before removing adapter.

Volkswagen Workshop Service and Repair Manuals