Turbocharger Vacuum Diaphragm, Adjusting

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Turbocharger removed

Special tools and workshop equipment 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

Adjusting

For the correct tightening specifications, refer to TURBOCHARGER OVERVIEW => Part IV .

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

Fig 1: Disconnecting Hose From Vacuum Diaphragm At Turbocharger

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-- Loosen the clamp over the linkage on the turbocharger.

-- Loosen lock nut -2-.

Fig 2: Identifying Lock Nut, Linkage From Turbocharger, Vacuum Diaphragm & Turbocharger

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-- Adjust the bypass flap -1- using the knurled nut -arrow- so that the flap can still just be turned by hand.

Fig 3: Identifying Bypass Flap Above Linkage Of Vacuum Diaphragm

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-- Install the lock nut hand-tight.

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

Fig 4: Connecting Hand Vacuum Pump VAS 6213, Turbocharger Tester V.A.G 1397A To Connection II And Pressure Regulator Valve VAS 6342

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-- Close VAS 6342 on lever -1-.

-- Adjust slide ring -1- on VAS 6213 to -B- position for "Pressure".

Fig 5: Adjusting Slide Ring On Hand Vacuum Pump VAS 6213 To Position For "Pressure"

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-- Switch on V.A.G 1397A and adjust slide switch to position II.

-- Secure VW 387 on turbocharger -arrow-.

Fig 6: Identifying Dial Gauge VAS 6341/1, Extension VAS 6341/3 And Level Tester VAS 6341/4 On Universal Dial Gauge Holder VW 387

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NOTE:

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 VW 387.

-- Set VAS 6341/1 to 1 mm tension at 0 bar.

-- Rotate VAS 6341/1 display to 0.

-- Check dial gauge for ease of movement.

-- Run the VAS 6213 until the V.A.G 1397A shows 460 +/- 5 mbar.

-- 4.1 mm to 4.3 mm must appear in the dial gauge; if not, turn the knurled nut until the value is displayed.

-- Tighten the lock nut hand-tight.

-- Repeat measurement.

-- Reduce pressure to 0 mbar via VAS 6342.

-- Set VAS 6341/1 to 0.

NOTE:

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

-- Run the VAS 6213 until the V.A.G 1397A shows 460 +/- 5 mbar.

-- Read and make a note of the value on VAS 6341/1.

-- Operate VAS 6213 until V.A.G 1397A displays 650 mbar to 700 mbar.

-- Reduce the pressure to 460 +/- 5 mbar using the VAS 6342.

-- Read and make a note of the value on VAS 6341/1.

-- Add value 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 lock nut hand-tight and repeat the measurement.

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

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

Fig 7: Identifying Securing Plate On Linkage To Turbocharger

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