Vacuum diaphragm for turbocharger, adjusting

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Turbocharger removed

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

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Special tools, testers and auxiliary items required

Dial gauge holder VW 387
Hand vacuum pump VAS 6213
Pressure regulator valve VAS 6342
Turbocharger tester V.A.G 1397A

Dial Gauge Set, 4-part VAS 6341
Torque wrench V.A.G 1783

Special tools, testers and auxiliary items required

Fig 2: Open End Spanner Insert AF 10 V.A.G 1783/1

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Open End Spanner Insert AF 10 V.A.G 1783/1

Adjusting

Tightening torques Part IV

Fig 3: Removing Hose From Vacuum Diaphragm On Turbocharger

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Remove hose - arrow - from vacuum diaphragm on turbocharger.

Fig 4: Removing Securing Plate Over Linkage On Turbocharger

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Remove securing plate - 1 - over linkage on turbocharger.

Fig 5: Identifying Lock Nut, Linkage From Turbocharger, Vacuum Diaphragm & Turbocharger

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Loosen lock nut - 2 -.

Fig 6: Pre-Adjusting Bypass Flap Above Linkage Of Vacuum Diaphragm

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

Fig 7: 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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Connect hand vacuum pump VAS 6213 , turbocharger tester V.A.G 1397A to connection II and pressure regulator valve VAS 6342 as depicted in the illustration.
Close Pressure Control Valve VAS 6342 on lever - 1 -.

Fig 8: Adjusting Slide Ring On Hand Vacuum Pump VAS 6213 To Position For "Pressure"

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Adjust slide ring - 1 - on Hand Vacuum Pump VAS 6213 to - B - position for "Pressure".
Switch on Turbocharger Tester V.A.G 1397A and adjust slide switch to position II.

Fig 9: Securing Dial Gauge VAS 6341/1 With 30 mm Extension VAS 6341/3 And Level Tester VAS 6341/4 On Universal Dial Gauge Holder VW 387

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Secure Dial Gauge Holder VW 387 on turbocharger - arrow -.

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 Dial Gauge Holder VW 387.
Set Dial Gauge 0-30 mm VAS 6341/1 to 1 mm pre-load with 0 bar on vacuum diaphragm.
Rotate Dial Gauge 0-30 mm VAS 6341/1 display to 0.
Check dial gauge for ease of movement.

Operate Hand Vacuum Pump VAS 6213 until Turbocharger Tester V.A.G 1397A shows 350 +/- 5 mbar.
Dial gauge must display between 4.1 mm and 4.33, otherwise, turn knurled nut until value is displayed.
Hand tighten lock nut.
Repeat measurement.

Reduce pressure to 0 mbar via Pressure Control Valve VAS 6342.
Set Dial Gauge 0-30 mm VAS 6341/1 to 0.

NOTE:

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

Operate Hand Vacuum Pump VAS 6213 until Turbocharger Tester V.A.G 1397A shows 350 +/- 5 mbar.
Read value on dial indicator VAS 6341/1 and note.
Operate Hand Vacuum Pump VAS 6213 until Turbocharger Tester V.A.G 1397A displays 650 mbar to 700 mbar.
Reduce pressure to 350 +/- 5 mbar via Pressure Control Valve VAS 6342.

Read value on dial indicator VAS 6341/1 and note.
Add value 1 and 2 and divide by 2.
The result (mean value) must be 5 +/- 0.25 mm.
If result (mean value) is not 5 +/- 0.25 mm, correct adjustment, tighten lock nut hand-tight and repeat measurement.

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

Fig 10: Removing Securing Plate Over Linkage On Turbocharger

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Secure securing plate - 1 - over vacuum diaphragm linkage.