Turbocharger Vacuum Diaphragm, Replacing, Cylinder Bank 2 (Left): Installing

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-- Bring the vacuum diaphragm -1- on the turbocharger into the installation position and tighten the nuts -arrows-.

• Do not attach the locking spring -2- on the operating lever yet.

-- Adjust the control rod so that the operating lever -1- lays on the stop -2-, as described as follows.

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-- Loosen the lock nut -2- to do so counterhold at the same time on the flattened position -arrow- of the eye -1- with an open end wrench.

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-- Adjust the length of the control rod by turning the eye.

-- Engage the control rod on the operating lever and tighten the lock nut.

• Do not attach the locking spring on the operating lever yet.

-- Clamp the small locking pliers -1- on the flattened position of the eye. The locking pliers function as a stop for the dial gauge.

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-- Tighten the Dial Gauge Holder:VW 387  on the engine lifting eye -2-.

-- Align the Dial Gauge Set - Dial Gauge:VAS 6341/1  in the Dial Gauge Holder:VW 387  so that the measuring probes are parallel to the vacuum diaphragm control rod at the same time the measuring probe contacts the locking pliers.

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

-- Connect the test equipment together as shown and on the Digital Pressure Sensor:V.A.G 1397B  as well as the turbocharger vacuum diaphragm.

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-- Close the lever -1- on the Pressure Control Valve:VAS 6342  .

-- Set the slider ring -1- on the Hand Vacuum Pump:VAS 6213  in position -A- for "vacuum".

Fig 1: Adjusting Hand Vacuum Pump Slide Ring

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-- Switch on the Digital Pressure Sensor:V.A.G 1397B  .

-- Generate a vacuum of -400 mbar (-5.8 psi) using the Hand Vacuum Pump:VAS 6213  .

-- Read out the entire adjustment range of the control rod on the dial gauge.

• Specified value 12 ± 0.5 mm

-- Open the test valve and reduce the vacuum to -350 mbar (-5.08 psi).

• The control rod must not move (visual inspection on the dial gauge).

-- Further reduce the vacuum to -320 mbar (-4.64 psi).

• The control rod starts to move.

-- Further reduce the vacuum to -200 mbar (-2.9 psi) and read the adjustment range on the dial gauge.

• Specified value 4 ± 0.3 mm

If the specified value is NOT attained:

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-- Remove the locking pliers.

-- Loosen the lock nut -2- to do so counterhold at the same time on the flattened position -arrow- of the eye -1- with an open end wrench.

-- Disengage the control rod on the operating lever.

-- Adjust the length of the control rod by turning the eye in 180°-steps.

-- Engage the control rod on the operating lever and tighten the lock nut.

• Do not attach the locking spring on the operating lever yet.

-- Repeat the test.

If specified value is obtained:

• Check the vacuum hose for damage before assembling and replace if necessary.

-- Remove the measurement setup.

-- Connect the vacuum hose on the vacuum diaphragm of the turbocharger. Refer to Figure.

-- Attach the locking spring on the operating lever.

-- Secure the lock nut on the control rod with sealing wax.

-- Install the turbocharger. Refer to TURBOCHARGER, INSTALLING .