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 1397 A)

• 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 the 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 hand vacuum pump (VAS 6213) , turbocharger tester (V.A.G 1397 A) and the pressure control valve (VAS 6342) to the connection as shown in the illustration.






- Close the pressure control valve (VAS 6342) using the lever - 1 -.

- Set the slide ring - 1 - on the hand vacuum pump (VAS 6213) to position - B - for "pressure".






- Turn on the turbocharger tester (V.A.G 1397 A) and set the slide switch to position II.

- Secure the dial gauge holder (VW 387) onto the turbocharger - arrow -.






- Secure the dial gauge 0-30 mm (VAS 6341/1) with the dial gauge extension 30 mm (VAS 6341/3) and the flat pickup (VAS 6341/4) on the dial gauge holder (VW 387).

- Set the dial gauge 0-30 mm (VAS 6341/1) to 0 bar with a 1 mm preload.

- Rotate the indicator on the dial gauge 0-30 mm (VAS 6341/1) to 0.

- Check the dial indicator for ease of movement.

- Operate the hand vacuum pump (VAS 6213) until the turbocharger tester (V.A.G 1397 A) displays 350 +/-5 mbar.

- The dial gauge 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 specification apply to the value read out (includes the 1 mm preload).

- Release the pressure via the pressure control valve (VAS 6342) to 0 mbar.

- Set the dial gauge 0-30 mm (VAS 6341/1) to 0.

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

- Operate the hand vacuum pump (VAS 6213) until the turbocharger tester (V.A.G 1397 A) displays 350 +/-5 mbar.

- Read and make a note of the value on the dial gauge 0-30 mm (VAS 6341/1).

- Operate the hand vacuum pump (VAS 6213) until the turbocharger tester (V.A.G 1397 A) displays 650 to 700 mbar.

- Release the pressure via the pressure control valve (VAS 6342) to 350 +/- 5 mbar.

- Read and make a note of the value on the dial gauge 0-30 mm (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 it with sealing wax.

- Secure the securing plate above the linkage of the vacuum diaphragm.