Turbocharger Vacuum Diaphragm, Replacing: Installing

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-- Install the vacuum diaphragm -2- with adjustable control rod on the turbocharger.

-- To do so, tighten the nuts -arrows- and press on the guide piece -1- on the operating lever pin.

-- Next mount the >>old<< clip -1- on the operating lever.

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-- Secure the locking pliers -1- on the guide piece shaft -2-. The locking pliers function as a stop for the dial gauge.

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-- Tighten the :VW387  on the retainer of the vacuum hose -2-. Remove the vacuum hose for this.

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-- Align the Dial Gauge Set - Dial Gauge:VAS6341/1  in the :VW387  so that the measuring probes are parallel to the vacuum diaphragm control rod at the same time the measuring probe contacts the locking pliers -1-.

-- Set the gauge with approximately 20 mm pretension to "0".

-- Connect the test equipment together as shown and on the :VAG1397A  as well as the turbocharger vacuum diaphragm.

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-- Close the lever -1- on the :VAS6342  .

-- Set the slider ring -1- on the :VAS6213  in position -A- for "vacuum".

Fig 1: Adjusting Hand Vacuum Pump Slide Ring

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-- Switch on the :VAG1397A  .

-- Use the :VAS6213  to generate a vacuum of minimum -360 (-5.2 psi) to -400 mbar (-5.8 psi) to close the door.

-- Open the test valve and reduce the vacuum slowly to 160 mbar (2.3 psi).

• At 155 (2.2 psi) to 165 mbar (2.39 psi) the dial gauge must have a stroke of 7.45 to 8.95 mm.

-- If required, loosen the lock nut -2- and adjust the guide piece -1-.

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-- Repeat the test.

-- Tighten the lock nut and mount the new clamp.

-- Remove the measurement setup and connect the vacuum hose on the vacuum diaphragm.

-- Install the air duct pipe and the hose clamps -1 and 2-.

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-- Tighten the bolt -arrow- and install the hose -3- for the crankcase ventilation on the ventilation pipe.

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .