Volkswagen Golf / Golf Plus. Manual - part 331

 

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Volkswagen Golf / Golf Plus. Manual - part 331

 

 

Note

There is a danger of a “hose detaching” whilst driving after re‐

moving and reinstalling charge pressure lines with spring-type

clamps. For this reason, spring band rings are used which can be

opened if a defect item requires the charge pressure line has to

be disconnected. In cases of repair, destroy the spring band ring

using a suitable tool and renew it with a replacement part from ⇒ 

ETKA (electronic parts catalogue) .

1.7

Checking charge air system for leaks

Special tools and workshop equipment required
♦ Charge air system tester -V.A.G 1687-
♦ Adapter -V.A.G 1687/10-
– Remove intake hose -1- from air filter.
– Insert adapter -V.A.G 1687/10- in intake hose -1- and secure

with clip.

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

– Turn pressure regulating valve -2- anti-clockwise onto stop.
– Close valves -3- and -4-.

Note

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

upwards.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

162

     Rep. Gr.21 - Turbocharging/supercharging

 

– 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 neces‐

sary readjust pressure to 0.5 bar.

– Check the charge air system for leaks by hearing, touching,

with leak detector spray or using ultrasonic tester -V.A.G

1842- .

Note

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

instructions

If leaks occur, when doing any repair work observe notes for

charge air system 

⇒ page 158

 .

Depressurise test circuit by detaching coupling from adapter -

V.A.G 1687/10- before removing adapter.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Charge air system with turbocharger    

163

 

Vehicles with particulate filter 

⇒ page 164

Vehicles without particulate filter 

⇒ page 165

1.8.1

Vehicles with particulate filter

1 - Turbocharger
2 - Connecting pipe air filter/

turbocharger
3 - Non-return valve

❑ Note installation posi‐

tion.

4 - To brake servo
5 - Charge pressure control

solenoid valve -N75-
6 - Air filter
7 - Cylinder head/cylinder

block
8 - Intake manifold
9 - Bypass flap

❑ For exhaust gas recircu‐

lation cooler.

10 - Cooler

❑ For exhaust gas recircu‐

lation.

11 - Exhaust gas recirculation

valve -N18-
12 - Exhaust gas recirculation

cooler change-over valve -

N345-
13 - Non-return valve

❑ Note installation posi‐

tion.

14 - Vacuum unit

❑ Turbocharger

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

164

     Rep. Gr.21 - Turbocharging/supercharging

 

1 - Solenoid valve block
2 - Non-return valve

❑ Note installation posi‐

tion.

3 - To brake servo
4 - Connecting pipe air filter/

turbocharger
5 - Air filter
6 - Intake manifold
7 - Cylinder head/cylinder

block
8 - Vacuum reservoir
9 - Bypass flap

❑ For exhaust gas recircu‐

lation cooler.

10 - Cooler

❑ For exhaust gas recircu‐

lation.

11 - Exhaust gas recirculation

valve -N18-
12 - Turbocharger
13 - Non-return valve

❑ Note installation posi‐

tion.

4-cylinder diesel engine (1.9 l engine) - Edition 01.2009

1. Charge air system with turbocharger    

165

 

 

 

 

 

 

 

 

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