Turbocharger Vacuum Diaphragm, Adjusting

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

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

Procedure

The turbocharger is removed, refer to TURBOCHARGER .
For the correct tightening specifications, refer to TURBOCHARGER OVERVIEW .

-- Remove the pressure hose -arrow-.

Fig 1: Locating Pressure Hose

Courtesy of AUDI OF AMERICA, LLC

-- Remove the linkage securing plate -2- from the turbocharger.

NOTE:

Ignore -1 and 3-.

-- Loosen the nut -2-.

Fig 2: Locating Turbocharger Linkage Nut

Courtesy of AUDI OF AMERICA, LLC

-- Adjust the bypass flap with the nut -3-.

It must still be possible to move the bypass flap by hand.

-- Tighten the nut -2- by hand.

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

Courtesy of AUDI OF AMERICA, LLC

-- Close the VAS 6342.

The lever -1- is horizontal.

-- Move the sliding ring -1- on the hand vacuum pump to the "Pressure" position -arrow B-.

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

-- Tighten the VW 387 on the turbocharger -arrow-.

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

Courtesy of AUDI OF AMERICA, LLC

-- Secure the dial gauge VAS 6341/1 with the dial gauge extension, 30 mm VAS 6341/3 and flat pickup VAS 6341/4 on the dial gauge holder as illustrated.

-- Set the dial gauge to 1 mm tension at 0 bar.

-- Rotate the dial gauge display to "0".

-- Check dial gauge for ease of movement.

-- Operate the hand vacuum pump until the turbocharger tester shows the following value:

500 to 5 mBar.

-- Read the value on the dial gauge:

Specified value 3.75 to 4.25 mm.

-- Rotate the nut -3- accordingly if the specified value is not reached or is exceeded.

Fig 5: Locating Turbocharger Linkage Nut

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the nut -2- by hand and repeat the measurement.

-- Reduce pressure to 0 mBar via the VAS 6342.

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

Courtesy of AUDI OF AMERICA, LLC

-- Set the dial gauge VAS 6341/1 to "0".

NOTE:

The following measurements must be performed in the order described. The pressure must not decrease to 0 mBar while performing the measurements.

-- Operate the VAS 6213 until the V.A.G 1397A shows the following value:

500 to 5 mBar.

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

-- Operate the hand vacuum pump until the turbocharger tester shows the following value:

650 to 700 mBar.

-- Reduce the pressure to 500 +/- 5 mBar with the VAS 6342.

-- Read and note the value on the dial gauge.

-- Add values "1" and "2" and divide by 2.

Specified value (average value) 4 +/- 0.25 mm.

-- Rotate the nut -3- accordingly if the specified value is not reached or is exceeded.

Fig 7: Locating Turbocharger Linkage Nut

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the nut -2- by hand and repeat the measurement.

-- If the specified value is reached, tighten the nut and secure with sealing wax; sealing wax.

-- Secure the securing plate -2- on the vacuum diaphragm linkage and install the pressure hose -arrow-.

Fig 8: Locating Pressure Hose

Courtesy of AUDI OF AMERICA, LLC