21-16

Charge pressure leak test with

VAG 1687

Intake system, checking for leaks using
VAG 1687 Diagnostic Tool
Diagnostic trouble codes (DTCs) related to fuel
trim, charge pressure or mass air flow (MAF)
may be caused by:

Leaking (worn/torn) intake hoses during charge
conditions

Incorrectly torqued or improperly placed clamps
on intake hoses etc. causing leaks during
charge conditions

Check the charge air pressure system using the VAG 1687 Charge air
system tester.
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 assembly.
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The shop air supply line will later be attached to the inlet of VAG 1687.
- Close valve -3- before gauge.
- Close valve -4- after gauge.
- Remove female fitting from tester (arrow) and install an appropriate
"male" air fitting that will connect to your shop air supply line (
WARNING!).
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21-17

WARNING!
Use only approved air fittings to adapt shop
air supply line to VAG 1687 tester.
Special tool VAG 1687/1 pressure adapter,
installing (1.8L Turbo)

- Separate intake hose from Mass Air Flow (MAF)
sensor assembly.

Special tool VAG 1687/1 pressure adapter, installing (2.7L BiTurbo)
Repair Manual, Maintenance; Air cleaner housing, cleaning; Air cleaner
element, replacing
- Insert VAG 1687/1 pressure adapter in intake hose -black arrow- using
existing clamp (as shown).
- Remove crankcase ventilation tube from intake hose at -white arrow-.
- Remove upper air cleaner housing and hoses to intake manifold as
necessary

- Insert VAG 1687/1 pressure adapter in intake hose -white arrow- using
existing clamp (as shown).
- Disconnect engine crankcase ventilation hose from intake manifold -
black arrow-.
-
Plug intake manifold fitting (for crankcase ventilation hose) with
appropriate hose and metal plug using clamps supplied with VAG
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1687/1 special tool kit.
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21-18

Note:

To help find small leaks, BEFORE pressurizing
the system fill system with smoke using special
tool KLI9210 and adapter KLI9210/50 as
described on Page 21-18 .

An ultrasonic detector may also be used to
detect extremely small leaks where smoke may
not be visible.
Special tool KLI9210 (Evaporative system
leak detector), connecting to 1.8L Turbo

- Install optional fitting LKI9210/50 on hose of
special tool KLI9210.

Special tool KLI9210 (Evaporative system leak detector), connecting
to 2.7L BiTurbo
- Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached
to VAG 1687/1 at arrow on 1.8L Turbo).
- Install optional fitting LKI9210/50 on hose of special tool KLI9210.

-
Connect KLI9210 to VAG 1687/1 adapter (KLI9210 is shown attached
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to VAG 1687/1 at arrow on 2.7L BiTurbo).
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21-19

Special tool LKI9210 (Evaporative system
leak detector), preliminary set-up

- Connect smoke generator leads to vehicle
battery.

With system filled with smoke:
Special tool VAG 1687, connecting to pressure adapter VAG 1687/1
(1.8L Turbo)
For illustrations purposes VAG is shown lying in the engine compartment.
In practice the tool should be hung from the hood.
- Turn valve to test -black arrow-.
- Press smoke generator button to fill system with smoke (see
instructions printed on tester).
- Remove smoke generator hose and connect VAG1687 quickly to
prevent smoke from leaking out Page 21-19 .
- Connect VAG 1687 quickly to prevent smoke from leaking out.

VAG 1687 is shown connected to VAG 1687/1 -black arrow-
Shop air supply will be connected to VAG 1687 -at white arrow-
- Perform pressure test Page 21-21 .
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21-20

Special tool VAG 1687, connecting to
pressure adapter VAG 1687/1 (2.7L BiTurbo)
For illustrations purposes VAG is shown lying in
the engine compartment. In practice the tool
should be hung from the hood.

- Connect VAG 1687 quickly to prevent smoke
from leaking out.

VAG 1687 is shown connected to VAG 1687/1 -black arrow-
Shop air supply will be connected to VAG 1687 -at white arrow-
- Perform pressure test Page 21-21 .
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21-21

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 Page
21-16 .

CAUTION!
- Open valve -3- between regulator valve and gauge.
- Adjust test pressure up to 0.5 bar ( CAUTION below) by turning
regulator valve -2-.
DO NOT pressurize the system above 0.5 bar!
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.
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21-22

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

- Readjust test pressure to 0.5 bar ( CAUTION
above) by turning regulator valve -2-.

- Listen for any very large intake leaks.
If smoke generator was used to fill the system
with smoke:

- Inspect intake system connections for smoke at
leaks.
Note:
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.
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With VAS 5051 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.
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21-23

Note:
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 diagnostic tool connected:

- Erase DTC memory.
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21-24


Mechanical air recirculation valve,
checking
Note:

The mechanical air recirculation valve is
upstream of the exhaust turbocharger. It is
opened via vacuum by the recirculating valve
for turbocharger -N249- under conditions of
overrun, idling and partial load. This reduces
the charge pressure upstream of the throttle
valve. A high turbocharger speed is thus
maintained.

Check the air recirculation valve if the engine is
not producing full power, or jerking when the
throttle is opened and closed.
Special tools and equipment

Hand vacuum pump VAG 1390
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21-25

Test sequence

If the air recirculation valve does not open and close as specified, or if the
valve plate does not seal properly when the valve is closed:
- Attach vacuum pump VAG 1390 to air recirculation valve.
- Actuate hand vacuum pump.
Air recirculation valve should open -arrow-
- Operate air vent valve on vacuum pump after about 30 seconds.
Air recirculation valve should close -arrow-
- Replace air recirculation valve and attach hose connections with hose
clamps.
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21-26


Recirculating valve for turbocharger -
N249-, checking
Special tools and equipment
VAG 1526 A
VAG 1527 B
VAG 1594 A
VAG 1598/31
VAS 5051 with VAS 5051/1
- or
VAG 1551 with VAG 1551/3 A
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21-27

Test requirements:

Vehicle diagnostic, testing and information
system VAS 5051 or VAG 1551 Scan Tool
connected.
Test sequence
Note:
The recirculating valve for turbocharger -N249-
and the wiring connections are monitored by the
engine control module.

- Read Diagnostic Trouble Code (DTC) memory
of engine control module.
If a DTC relating to the recirculating valve for
turbocharger -N249- is displayed:

Note:
The illustration shows bottom view of removed intake line.
- Remove hoses of recirculating valve for turbocharger -N249- (-1-). The
electrical connector remains plugged in.
Location: below intake line
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21-28


- Connect auxiliary hose to valve connector marked with an arrow.
- Initiate output Diagnostic Test Mode (DTM) and activate recirculating
valve for turbocharger -N249-.
Output Diagnostic Test Mode
Recircul . valve for turbocharger -N249-

Display:
If the injector does not click:
If valve does not open or close properly:
The valve should click ...
... and must open and close (check by blowing into the auxiliary
hose).
- Check internal resistance of valve.
- Replace recirculation valve for turbocharger -N249-.
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21-29

Checking internal resistance

- Disconnect connector from recirculation valve for turbocharger -N249-
(-1-).

If specified value is not attained:
If specified value is attained:
- Connect multimeter to injector to measure resistance.
Specified value: 27 to 30
- Replace recirculating valve for turbocharger -N249-.
- Check power supply.
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21-30

Checking power supply
Note:
The power supply for the recirculating valve is via
the fuel pump relay.
Test requirements:

Fuse for recirculating valve OK.

Electrical Wiring Diagrams, Troubleshooting &
Component Locations binder

Fuel pump relay OK.

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Engine Code(s): AWM,
Repair Group 24

- Disconnect wiring connector from valve.

- Connect voltage tester VAG 1527 B as follows:
Connector Measure to
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contact
1 Engine Ground
- Operate starter briefly.
The LED must light up.
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21-31

If the LED does not light up:

- Check wiring from contact 1 on connector via
fuse to fuel pump relay for an open circuit:

Electrical Wiring Diagrams, Troubleshooting &
Component Locations binder

- Repair open circuit, if necessary.
If the LED lights up:

- Check actuation.
Checking actuation

- Connect voltage tester VAG 1527 B to contacts 1 (positive) and 2 of
connector.
- Initiate output Diagnostic Test Mode (DTM) and activate recirculatiing
valve for turbocharger -N249-.
The LED must flash.
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21-32

If the LED lamp does not flash or if it lights up
continuously:

- Connect VAG 1598/31 test box to wiring
harness leading to engine control module;
engine control module should not be connected:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Engine Code(s): AWM,
Repair Group 24

If the wiring is OK:
- Check for open circuit and short to positive or Ground in following
wiring connection:
Connector
Contact
Test box VAG 1598/31
2 105
- Repair any open/short circuit as necessary.
- Replace engine control module.
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21-33


Wastegate Bypass Regulator valve -N75-,
checking
Special tools and equipment
VAG 1526 A
VAG 1527 B
VAG 1594 A
VAG 1598/31
VAS 5051 with VAS 5051/1
- or
VAG 1551 with VAG 1551/3 A
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21-34

Test requirements:

Vehicle diagnostic, testing and information
system VAS 5051 or VAG 1551 Scan Tool
connected.
Test sequence
Note:
The Wastegate Bypass Regulator valve -N75-
and the wiring connections are monitored by the
engine control module.

- Read Diagnostic Trouble Code (DTC) memory
of engine control module.
If a DTC relating to the Wastegate Bypass
Regulator valve -N75 is displayed:

- Disconnect hoses from valve but leave electrical
connector attached.

- Connect auxiliary hose to valve connector marked with an arrow.
- Initiate output Diagnostic Test Mode (DTM) and actuate Wastegate
Bypass Regulator valve -N75-.
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21-35

Output Diagnostic Test Mode
-N75- wastegate bypass regul ator valve

Display
If the injector does not click:
If valve does not open or close properly:
Checking internal resistance
The valve must click ...
... and must open and close (check by blowing into the auxiliary
hose).
- Check internal resistance of valve.
- Replace Wastegate Bypass Regulator valve -N75-.
- Disconnect connector from valve.

If specified value is not attained:
If specified value is attained:
- Connect multimeter to injector to measure resistance.
Specified value: 25 to 35
- Replace Wastegate Bypass Regulator valve -N75-.
- Check power supply.
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21-36

Checking power supply
Test requirements:

Fuse for wastegate bypass regulator valve
OK

Electrical Wiring Diagrams, Troubleshooting &
Component Locations binder

Fuel pump relay OK.

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Engine Code(s): AWM,
Repair Group 24

- Connect voltage tester VAG 1527 B as follows:
Connector
contact
Measure to
1 Engine Ground
- Operate starter briefly.
LED must light up.
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21-37

If the LED does not light up:

- Check wiring from contact 1 on connector via
fuse to fuel pump relay for open circuit:

Electrical Wiring Diagrams, Troubleshooting &
Component Locations binder

- Repair open circuit, if necessary
If the LED lights up:

- Check actuation.
Checking actuation

- Connect voltage tester VAG 1527 B to contacts 1 (positive) and 2 of
connector.
- Initiate output Diagnostic Test Mode (DTM) and actuate Wastegate
Bypass Regulator valve -N75-.
Output Diagnostic Test Mode

Display
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-N75- wastegate bypass regul ator valve
LED must flash.
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21-38

If the LED lamp does not flash or if it lights up
continuously:

- Connect VAG 1598/31 test box to wiring
harness leading to engine control module;
engine control module should not be connected:

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel
Injection & Ignition, Engine Code(s): AWM,
Repair Group 24

If the wiring is OK:
- Check for open circuit and short to positive or Ground in following
wiring connection:
Connector
Contact
Test box VAG 1598/31
2 104
- Repair any open/short circuit as necessary.
- Replace engine control module.
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21-39


Charge Air Pressure sensor -G31-,
checking
Special tools and equipment
VAG 1526 A
VAG 1594 A
VAG 1598/31
VAS 5051 with VAS 5051/1
- or
VAG 1551 with VAG 1551/3 A
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21-40

Test requirements:

Vehicle diagnostic, testing and information
system VAS 5051 or VAG 1551Scan Tool
connected.
Test sequence
Note:
The Charge Air Pressure sensor -G31- and the
wiring connections are monitored by the engine
control module.

- Read Diagnostic Trouble Code (DTC) memory
of engine control module.
If a DTC relating to the Charge Air Pressure
sensor -G31- is displayed:
Checking power supply

- Disconnect connector -arrow- on charge pressure sender.
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If specified value is not attained:
- Connect multimeter between contacts 1 and 3 of connector to measure
voltage.
- Switch ignition on.
Specified value: approx. 5 V

Repair Manual, 1.8 Liter 4-Cyl. 5V Turbo Fuel Injection & Ignition,
Engine Code(s): AWM, Repair Group 24
- Connect VAG 1598/31 test box to wiring harness leading to engine
control module; engine control module must also be connected.
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21-42


If specified value is attained:
Checking signal wire
- Check for open circuit and short to positive or Ground in following
wiring connections:
Connector
contact
Test box VAG 1598/31
1 108
3 98
- Repair any open/short circuit as necessary.
- Attach connector from charge air pressure sensor.
- Attach multimeter for voltage test to socket 101 and socket 108 of test
box.
- Start engine and run at idling speed.
Specified value: approx. 1.90 V
- Bring engine to speed by spontaneous acceleration.
Specified value: 2.00...3.00 V
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21-43

If specified values are not attained:

If the wiring is OK:
- Check for open circuit and short to positive or Ground in following
wiring connection:
Connector
contact
Test box VAG 1598/31
4 101
- Repair any open/short circuit as necessary.
- Replace Charge Air Pressure sensor -G31-.
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