Wastegate Actuator: Adjustments

Turbocharger Exhaust Vacuum Diaphragm, Adjusting

Turbocharger removed

Special tools, testers and auxiliary items required

• Dial gauge holder (VW 387)

• Hand vacuum pump (VAS 6213)

• Pressure regulator valve (VAS 6342)

• Turbocharger tester (V.A.G 1397A)

• Dial Gauge Set, 4-part (VAS 6341)

• Torque wrench (V.A.G 1783)

• Open End Spanner Insert AF 10 (V.A.G 1783/1)

Adjusting

• Tightening specifications => [ Part IV ] Turbocharger Component Overview

- Remove hose - arrow - from vacuum diaphragm on turbocharger.





- Remove securing plate - 1 - over linkage on turbocharger.





- Loosen lock nut - 2 -.





- Pre-adjust bypass flap - 1 - via knurled nut - arrow - so flap can still just be turned by hand.





- Install lock nut hand tight.

- Connect hand vacuum pump (VAS 6213), turbocharger tester (V.A.G 1397A) to connection II and pressure regulator valve (VAS 6342) as depicted in the illustration.





- Close Pressure Control Valve (VAS 6342) on lever - 1 -.

- Adjust slide ring - 1 - on Hand Vacuum Pump (VAS 6213) to - B - position for " Pressure".





- Switch on Turbocharger Tester (V.A.G 1397A) and adjust slide switch to position II.

- Secure Dial Gauge Holder (VW 387) on turbocharger - arrow -.





• The mm specifications apply to the value read out (includes 1 mm pre-load).

- Secure Dial Gauge 0-30 mm (VAS 6341/1) with Dial Gauge Extension, 30 mm (VAS 6341/3) and Flat Pickup (VAS 6341/4) to Dial Gauge Holder (VW 387).

- Set Dial Gauge 0-30 mm (VAS 6341/1) to 1 mm pre-load with 0 bar on vacuum diaphragm.

- Rotate Dial Gauge 0-30 mm (VAS 6341/1) display to 0.

- Check dial gauge for ease of movement.

- Operate Hand Vacuum Pump (VAS 6213) until Turbocharger Tester (V.A.G 1397A) shows 350 +/- 5 mbar.

- Dial gauge must display between 4.1 mm and 4.33, otherwise, turn knurled nut until value is displayed.

- Hand tighten lock nut.

- Repeat measurement.

- Reduce pressure to 0 mbar via Pressure Control Valve (VAS 6342).

- Set Dial Gauge 0-30 mm (VAS 6341/1) to 0.

• The following measurements must be performed in one sequence. In the meantime, pressure must not dissipate to 0.

- Operate Hand Vacuum Pump (VAS 6213) until Turbocharger Tester (V.A.G 1397A) shows 350 +/- 5 mbar.

- Read value on dial indicator (VAS 6341/1) and note.

- Operate Hand Vacuum Pump (VAS 6213) until Turbocharger Tester (V.A.G 1397A) displays 650 mbar to 700 mbar.

- Reduce pressure to 350 +/- 5 mbar via Pressure Control Valve (VAS 6342).

- Read value on dial indicator (VAS 6341/1) and note.

- Add value 1 and 2 and divide by 2.

- The result (mean value) must be 5 +/- 0.25 mm.

- If result (mean value) is not 5 +/- 0.25 mm, correct adjustment, tighten lock nut hand-tight and repeat measurement.

- If result (average) is 5 +/- 0.25 mm, tighten lock nut and secure with sealing wax.

- Secure securing plate - 1 - over vacuum diaphragm linkage.