Turbocharger Vacuum Diaphragm, Adjusting

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NOTE:

This procedure description is only for 1.8L engines.

Fig 1: Identifying Special Tools - Vacuum Diaphragm For Turbocharger, Adjusting

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Special tools and workshop equipment required

Dial Gauge Holder VW387
Hand Vacuum Pump VAS6213
Pressure Control Valve VAS6213
Turbocharger Tester Kit VAG1397A
Dial Gauge Set VAS6341
Torque Wrench 1783 - 2-10Nm VAG1783

Special tools and workshop equipment required

Torque Wrench 1783 - Open Jaw - 10mm VAG1783/1

Fig 2: Open Jaw - 10mm VAG1783/1
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Adjusting

Turbocharger removed.

NOTE:

It is necessary to adjust the diaphragm only if it has been removed.

-- Pre-adjust bypass flap -1- via nut -arrow- so flap can still just be turned by hand.

Fig 3: Identifying Bypass Flap Above Linkage Of Vacuum Diaphragm

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-- Secure the Dial Gauge Holder VW387 onto the turbocharger -arrow-.

Fig 4: Securing Dial Gauge Onto Turbocharger -Arrow-

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NOTE:

The mm specifications apply to the value read out (includes 1 mm pre-load).

The Dial Gauge Set - Dial Gauge VAS6341/1 with Dial Gauge Set - Extension - 30mm VAS6341/3 must align with the linkage on the vacuum diaphragm.

-- Secure the Dial Gauge Set - Dial Gauge VAS6341/1 with the Dial Gauge Set - Extension - 30mm VAS6341/3 and Dial Gauge Set - Flat Pickup VAS6341/4 to the Dial Gauge Holder VW387.

-- Set the Dial Gauge Set - Dial Gauge VAS6341/1 to 1 mm pretension.

-- Turn the Dial Gauge Set - Dial Gauge VAS6341/1 display to 0.

-- Check dial gauge for ease of movement.

-- Turn the nut -1- approximately 7 turns in -direction of arrow-.

Fig 5: Adjusting Dial Gauge

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-- Turn the nut -2- in -direction of arrow- until the dial gauge shows 7 mm.

-- Hand-tighten the nut -1-.

-- Set the Dial Gauge Set - Dial Gauge VAS6341/1 to 1 mm pretension.

-- Turn the Dial Gauge Set - Dial Gauge VAS6341/1 display to 0.

-- Connect the Hand Vacuum Pump VAS6213, the Turbocharger Tester Kit VAG1397A to connection II and the Seal Installer - Crankshaft VAS6213 as shown in the illustration.

Fig 6: Connecting VAS6213, VAG1397A To Connection II And VAS6342

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-- Switch the Turbocharger Tester Kit VAG1397A and set the slide switch to position II.

-- Close the Pressure Control Valve VAS6213 on the lever -1-.

-- Set the slide ring -1- on the Hand Vacuum Pump VAS6213 in position -B- for "pressure".

Fig 7: Adjusting Hand Vacuum Pump Slide Ring

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NOTE:

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

-- Operate the Hand Vacuum Pump VAS6213 until the Turbocharger Tester Kit VAG1397A displays 460 +/- 5 mbar.

NOTE:

If 460 ± 5 mbar is exceeded, then the measuring must be started again from the beginning.

-- Read and note the value on the Dial Gauge Set - Dial Gauge VAS6341/1.

-- Operate the Hand Vacuum Pump VAS6213 until the Turbocharger Tester Kit VAG1397A displays 650 mbar to 700 mbar.

-- Reduce the pressure to 460 +/- 5 mbar via Pressure Control Valve VAS6213.

NOTE:

If 460 ± 5 mbar is not reached, then the measuring must be started again from the beginning.

-- Read and note the value on the Dial Gauge Set - Dial Gauge VAS6341/1.

-- Add value 1 and 2 together and divide by two.

-- The result (mean value) must be 5 +/- 0.5 mm.

-- If the value is greater, then lower the pressure to 0 bar, loosen the nut -1- and turn the nut -2- a half a turn and then tighten the nut -1- hand-tight.

Fig 8: Adjusting Dial Gauge

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-- Set the Dial Gauge Set - Dial Gauge VAS6341/1 to 1 mm pretension.

-- Turn the Dial Gauge Set - Dial Gauge VAS6341/1 display to 0 and repeat the measurement.

-- If the average value is 5 ± 0.5 mm, then tighten the lock nut and repeat the measurement.

-- If the average value is 5 ± 0.5 mm, then secure the nuts with sealing wax. Sealing wax.

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

Fig 9: Identifying Securing Plate On Linkage To Turbocharger

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Tightening Specifications

Turbocharger vacuum diaphragm OVERVIEW - TURBOCHARGER - Part IV - 1.8L Engine Only .