Intake System, Checking For Leaks Using The VAG Diagnostic Tool (GROUP 24, NO. 07-06)

SPECIAL TOOL VAG 1687 CHARGE AIR SYSTEM TESTER, PRELIMINARY SET-UP

• Back off pressure regulator knob -2- of VAG 1687 fully to protect gauge when shop air supply is applied to the assembly.
• Close valve -3- before gauge.
• Close valve -4- after gauge.

  Shop air supply line will later be attached to inlet of VAG 1687.

• Remove "female" fitting from tester (arrow) and install an appropriate "male" air fitting that will connect to your shop air supply line (See Note).
  Fig 2: VAG 1687 Charge Air System Tester Assembly

  

SPECIAL TOOL VAG 1687/1 PRESSURE ADAPTER, INSTALLING

On Golf, Jetta and New Beetle Models:

• Separate intake hose from the Mass Airflow Sensor assembly (MAF).
• Insert VAG 1687/1 pressure adapter in intake hose -black arrow- using existing clamp (as shown).
• Remove crankcase ventilation valve or tube from intake hose at -white arrow-.
• Plug hose with appropriate metal plug and hose clamps supplied with VAG 1687/1 special tool kit at -white arrow-.
Fig 3: Pressure Adapter Installation (Golf, Jetta and New Beetle)

On Passat models:

• Separate intake hose from the Mass Airflow Sensor assembly (MAF).
• Insert VAG 1687/1 pressure adapter in intake hose -black arrow- using existing clamp (as shown).
• Remove crankcase ventilation valve or tube from intake hose at -white arrow-.
• Plug hose with appropriate metal plug and hose clamps supplied with VAG 1687/1 special tool kit at -white arrow-.
Fig 4: Pressure Adapter Installation (Passat)

• Remove oil cap.

An Ultrasonic detector may also be used to detect extremely small leaks where smoke may not be visible.

SPECIAL TOOL KLI9210 (EVAP SYSTEM LEAK DETECTOR)

• Install optional fitting KLI 9210/50 on hose of special tool KLI9210.
• Connect KLI9210 to VAG 1687/1 adapter (KLI 9210 is shown attached to VAG1687/1 at arrow on 1.8L Turbo).
  Fig 5: EVAP System Leak Detector Connection

  

SPECIAL TOOL KLI9210 (EVAP SYSTEM LEAK DETECTOR), PRELIMINARY SET-UP

• Setup KLI 9210 as described in user manual regarding self-test and output pressure.
• Connect smoke generator leads to vehicle battery.
• Turn valve to test (black arrow).
• Press smoke generator button to fill system with smoke (see instructions printed on tester).
• Check for escaping smoke for two minutes.
  Fig 6: Valve Turned To Test

  

  Tip:  Smoke may escape from crankcase hose or oil fill hole. This is normal.

  With system filled with smoke:

• Remove smoke generator hose and connect VAG 1687 quickly to prevent smoke from leaking out.
• Connect VAG 1687 quickly to prevent smoke from leaking out.

SPECIAL TOOL VAG 1687 CONNECTING TO PRESSURE ADAPTER 1687/1

VAG 1687 is shown connected to VAG 1687/1 (black arrow)

Shop air supply connected to VAG 1687 at (white arrow).

• Perform pressure test.
  Fig 7: Pressure Adapter Connection

  

PERFORMING PRESSURE TEST

• With outlet hose -1- of VAG 1687 connected to air pressure adapter.
• Attach shop air supply line to previously installed male fitting.
  Fig 8: VAG 1687 Charge Air System Tester Assembly

  
• Open valve -3- between regulator valve and gauge.
• Adjust test pressure up to 0.5 bar (see Note below) by turning the regulator valve -2-.
  NOTE: DO NOT pressurize system above 0.5bar.
  Doing so may force oil into the intake system which can damage the engine.
• Slowly open outlet valve -4- (after gauge) to test hose connections.
• Observe pressure gauge for a drop in pressure.
  Fig 9: VAG 1687 Charge Air System Tester Assembly

  

Tip:  Some pressure will be lost past the throttle plate.

• Readjust test pressure to 0.5 bar (see CAUTION above) by turning the regulator valve -2-.
• Listen for any very large intake leaks.

  If smoke generator was used to fill the system with smoke:

• Check for smoke escaping from intake connections.

  Tip:  An Ultrasonic detector may also be used to detect extremely small leaks where smoke may not be visible.

• Repair any leaks found.
• Remove tester.
• Remove plug from crankcase ventilation hose.
• Remove air pressure adapter.

  With VAS 5051/5052 diagnostic tool connected:

• Erase DTC memory.

  If smoke generator was not used to fill the system with smoke:

• Apply soapy water solution or equivalent to intake system connections.

  Tip:  An Ultrasonic detector may also be used to detect extremely small leaks.

• Inspect intake system connections for leaks.
• Repair any leaks found.
• Remove tester.
• Remove plug from crankcase ventilation hose.
• Remove air pressure adapter.

  With VAS 5051/5052 diagnostic tool connected:

• Erase DTC memory.

  If no leaks are found, but complaint still exists, refer to Repair Group 21 in ElsaWeb for detailed testing of charge system components.