Volkswagen Golf Service & Repair Manual: Checking charge air system for leaks

Volkswagen Golf Service & Repair Manual / 4- cylinder injection engine(1.4 1 direct inction. turbocharger) / Exhaust turbocharger, g-charger / Charge air system / Checking charge air system for leaks

Special tools and workshop equipment required

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

Procedure

–	Release hose clips -1- and -2-, and remove air pipe.

Checking charge air system for leaks

–	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.

Checking charge air system for leaks

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

–	Unscrew pressure control valve -2- completely, 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.

Note

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

–	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, readjust pressure to 0.5 bar.

–	Check charge air system for leaks by listening, touching, with commercially available leak detector spray or using ultrasonic tester -V.A.G 1842-.

Note

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

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

Before removing the adapter, release pressure in the test circuit by pulling off hose coupling.

Installation is carried out in the reverse order; note the following:

Note

Renew seal and O-rings.

Specified torques

→ Fig. „“Installing air ducts with screw-type clips”“

Checking charge air system for leaks

Removing and installing charge air cooler

Special tools and workshop equipment required Hose clamps up to 25 mm -3094- ...

Mixture preparation system, electronic inj., Gas

...

Other materials:

Fitting control unit to hydraulic unit
Special tools and workshop equipment required ESD workplace -VAS 6613- Torque screwdriver -V.A.G 1624- Torx bit T25 Severe ...

Wheel change, position of anti-theft wheel bolts for steel wheels
Caution Adherence to position of anti-theft wheel bolts to tyre valve on steel wheels is vital. Anti-theft wheel bolts may only be fitted on ...

Checklist
The following actions must always be carried out in the given order in preparation for filling a tyre : If you get a flat tyre, park your vehicle on a firm and level surface at a safe distance from the flow of traffic. Switch on the electronic parking brake Braking, stopping and ...