Turbocharger Vacuum Diaphragm, Replacing, 3.0L Engine: Installing

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

-- To do so tighten the nuts -1 and 2- and press on the ball socket -3- on the operating lever ball pin.

-- Install the oil filter element. Refer to ENGINE OIL .

-- Adjust the control rod on the threaded piece so that the operating lever -1- contacts the stop -2-.

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-- Turn the threaded piece -2- out of this position 1.5 turns counter-clockwise.

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• The control rod is longer from this.

-- Tighten the lock nuts -1 and 3-.

-- Tighten the small locking pliers -1- on the shaft of the ball socket -2-. The locking pliers function as a stop for the dial gauge.

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-- Tighten the Dial Gauge Holder:VW387  on the engine lifting eye -2-.

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-- Align the Dial Gauge Set - Dial Gauge:VAS6341/1  in the Dial Gauge Holder: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 Digital Pressure Sensor:VAG1397B  as well as the turbocharger vacuum diaphragm.

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-- Close the lever -1- on the Pressure Control Valve:VAS6342  .

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

Fig 1: Adjusting Hand Vacuum Pump Slide Ring

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-- Switch on the Digital Pressure Sensor:VAG1397B  .

-- Generate a vacuum of -300 mbar (-4.35 psi) with the Hand Vacuum Pump:VAS6213  .

-- Slowly open the test valve and reduce the vacuum:

• Latest from -200 mbar (2.9 psi) the control rod begins to move.
• At 165 to 175 mbar (2.39 to 2.54 psi) on the gauge a stroke of 7 to 9 mm must be read.
• At 95 to 105 mbar (1.38 to 1.52 psi) on the gauge a stroke of 2 to 4 mm must be read.

-- If necessary, loosen the lock nuts -1 and 3- and adjust the threaded piece -2-.

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-- Repeat the test.

-- Tighten the lock nuts.

• The ball socket must be parallel to the operating lever.

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• Check the vacuum hoses for damage before the assembly and replace if necessary.

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

-- Install the oil filter element. Refer to ENGINE OIL .

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