Turbocharger Vacuum Diaphragm, Adjusting

WARNING: This page is about a different variant/trim than selected.

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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