Turbocharger Vacuum Diaphragm, Adjusting

WARNING: This page is about a different car, the 2009 Audi TT and 2008 Audi TT. However, it is still accessible from the selected car via links, so may be relevant.

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 5-60 Nm V.A.G 1783
Open End Spanner Insert AF 10 V.A.G 1783/1

Adjusting

For the correct tightening specifications PART IV

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

Fig 1: Disconnecting Hose From Vacuum Diaphragm At Turbocharger

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-- Remove securing plate -1- over linkage on turbocharger.

Fig 2: Removing Securing Plate Over Linkage On Turbocharger

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-- Loosen lock nut -2-.

Fig 3: 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 4: Identifying Bypass Flap Above Linkage Of Vacuum Diaphragm

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-- Install the lock nut hand-tight.

-- Connect the VAS 6213, V.A.G 1397A to connection II and the VAS 6342 as depicted in the illustration.

Fig 5: 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 the VAS 6342 on lever -1-.

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

Fig 6: Adjusting Slide Ring On Hand Vacuum Pump VAS 6213 To Position For "Pressure"

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

-- Secure VW 387 on turbocharger -arrow-.

Fig 7: 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 the dial gauge 0-30 mm VAS 6341/1 with the dial gauge extension, 30 mm VAS 6341/3 and flat pickup VAS 6341/4 to the VW 387.

-- Set the VAS 6341/1 to 1 mm pre-load at 0 bar.

-- Rotate the VAS 6341/1 display to 0.

-- Check dial gauge for ease of movement.

-- Run the VAS 6213 until the V.A.G 1397A shows 350 +/- 5 mbar.

-- The dial gauge must display between 4.1 mm and 4.33. 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 the 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 350 +/- 5 mbar.

-- Read and make a not of the value on dial indicator VAS 6341/1.

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

-- Reduce the pressure to 350 +/- 5 mbar using the VAS 6342.

-- Read and make a not of the value on the 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. Sealing wax.

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

Fig 8: Removing Securing Plate Over Linkage On Turbocharger

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