Wastegate Actuator: Adjustments
Turbocharger Vacuum Diaphragm, Adjusting
Special tools, testers and auxiliary items required
• Pressure Control Valve (VAS 6342)
• Dial Gauge Set, 4 Part (VAS 6341)
• Hand Vacuum Pump (VAS 6213)
• Turbocharger Tester (V.A.G 1397A)
• Dial Gauge Holder (VW 387)
• This procedure adjusts the vacuum diaphragm. The values may differ when testing a vacuum diaphragm that has already been adjusted.
• The vacuum diaphragm must be adjusted only if the linkage was loosened.
• Adjustment is performed only with turbocharger removed.
- Disconnect the hose - arrow - from the vacuum diaphragm.
- Loosen the clip above the linkage on the turbocharger.
- Loosen the lock nut - 2 -.
- Adjust the bypass flap - 1 - above the vacuum diaphragm linkage - arrow - so the bypass flap can still be turned by hand.
- Tighten the lock nut by hand.
- Connect the (VAS 6213) and the (V.A.G 1397A) to the T connection and the (VAS 6342) as shown in the illustration.
- Close pressure regulator valve at the lever - 1 -.
- Set the slide ring - 1 - on the (VAS 6213) to position - B - for "pressure".
- Turn on the (V.A.G 1397A) and set the slider switch to position II.
- Install the (VW 387) on the turbocharger - arrow -.
- Secure the (VAS 6341/1) with the (VAS 6341/3) and the (VAS 6341/4) to the (VW 387).
- Set the (VAS 6341/1) to 0 bar with 1 mm preload.
- Rotate the indicator on the (VAS 6341/1) to 0.
- Check the (VAS 6341/1) for ease of movement.
- Operate the (VAS 6213) until the (V.A.G 1397A) displays 350 +/-5 mbar.
- The (VAS 6341/1) must display 4.1 mm to 4.3 mm, otherwise rotate the linkage of the vacuum diaphragm until the value is displayed.
- Tighten the lock nut by hand.
- Repeat the measurement.
• The mm specifications apply to the value read out (includes 1 mm preload).
- Release pressure via (VAS 6342) to 0 mbar.
- Set the (VAS 6341/1) to 0.
• The following measurements must be performed in one sequence. In the meantime, pressure must not dissipate to 0.
- Operate the (VAS 6213) until the (V.A.G 1397A) displays 350 +/-5 mbar.
- Read and make a not of the value on the (VAS 6341/1).
- Operate the (VAS 6213) until the (V.A.G 1397A) displays 650 to 700 mbar.
- Release the pressure via the (VAS 6342) to 350 +/- 5 mbar.
- Read and make a not of the value on the (VAS 6341/1).
- Add values 1 and 2 and divide by 2.
- The result (mean value) must be 5 +/- 0.25 mm.
- If the result (mean value) is not 5 +/- 0.25 mm, correct the adjustment, tighten the lock nut by hand and repeat the measurement.
- If the result (mean value) is 5 +/- 0.25 mm, tighten the lock nut to 5 Nm and secure with sealing wax.
- Secure the securing plate above linkage of the vacuum diaphragm.