Turbocharger: Adjustments

Turbocharger Vacuum Diaphragm, Adjusting

Special tools, testers and auxiliary items required

• Dial Gauge Holder (VW 387)

• Hand Vacuum Pump (VAS 6213)

• Pressure Control 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)

Procedure

• The turbocharger is removed, refer to => [ Turbocharger ] Turbocharger.

• For the correct tightening specifications, refer to => [ Turbocharger Overview ] Turbocharger Overview.

- Remove the pressure hose - arrow -.






- Remove the linkage securing plate - 2 - from the turbocharger.

• Ignore - 1 and 3 -.

- Loosen the nut - 2 -.






- Adjust the bypass flap with the nut - 3 -.

• It must still be possible to move the bypass flap by hand.

- Tighten the nut - 2 - by hand.

- Connect the (VAS 6213) and the (VAS 6342) to the vacuum diaphragm and to connection "II" on the (V.A.G 1397A) as illustrated.






- Close the (VAS 6342).

• The lever - 1 - is horizontal.

- Move the sliding ring - 1 - on the hand vacuum pump to the "Pressure" position - arrow B -.

- Switch the (V.A.G 1397A) and adjust the slide switch to position "II".

- Tighten the (VW 387) on the turbocharger - arrow -.






- Secure the dial gauge (VAS 6341/1) with the dial gauge extension, 30 mm (VAS 6341/3) and flat pickup (VAS 6341/4) on the dial gauge holder as illustrated.

- Set the dial gauge to 1 mm tension at 0 bar.

- Rotate the dial gauge display to "0".

- Check dial gauge for ease of movement.

- Operate the hand vacuum pump until the turbocharger tester shows the following value:

• 500 to 5 mbar.

- Read the value on the dial gauge:

• Specified value 3.75 to 4.25 mm.

- Rotate the nut - 3 - accordingly if the specified value is not reached or is exceeded.






- Tighten the nut - 2 - by hand and repeat the measurement.

- Reduce pressure to 0 mbar via the (VAS 6342).






- Set the dial gauge (VAS 6341/1) to "0".

• The following measurements must be performed in the order described. The pressure must not decrease to 0 mbar while performing the measurements.

- Operate the (VAS 6213) until the (V.A.G 1397A) shows the following value:

• 500 to 5 mbar.

- Read and make a note of the value on dial indicator (VAS 6341/1).

- Operate the hand vacuum pump until the turbocharger tester shows the following value:

• 650 to 700 mbar.

- Reduce the pressure to 500 +/- 5 mbar with the (VAS 6342).

- Read and note the value on the dial gauge.

- Add values "1" and "2" and divide by 2.

• Specified value (average value) 4 +/- 0.25 mm.

- Rotate the nut - 3 - accordingly if the specified value is not reached or is exceeded.






- Tighten the nut - 2 - by hand and repeat the measurement.

- If the specified value is reached, tighten the nut and secure with sealing wax; sealing wax. Refer to the electronic parts catalog ETKA.

- Secure the securing plate - 2 - on the vacuum diaphragm linkage and install the pressure hose - arrow -.