Adjusting Bypass Flap Control Box

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Actuating lever at stop

This makes the control rod longer. 

1. 2.1  Tighten lock nuts -1 and 3-  .

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   Control rod and lock nuts

The clamping pliers serves as a stop for the dial gauge. 

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Clamping pliers on control rod

1. 4.1  > VW387 - Universal dial gauge bracket  must be secured to the engine transport eyebolt -2-  .
2. 4.2  Align the > VAS 6079 - Dial gauge  in the > VW387 - universal dial gauge bracket  in such a way that the measuring sensor is positioned as parallel as possible to the pressure unit and the measuring sensor is touching the clamping pliers -1- 
3. 4.3  Set the dial gauge to "0" with a preload of about 20 mm.

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Measurement setup

1. 5.1  Set > VAS 6213 - hand vacuum pump-1-  to vacuum. 
2. 5.2  Switch on > V.A.G 1397B - pressure sensor-2-  and set it to relative pressure. 
3. 5.3  Connect > VAS 6342 - pressure control valve-3-  to the vacuum connection of the control box.
4. 5.4  Create a vacuum of at least 300 mbar on the control box.
5. 5.5  Reduce the vacuum to 200 mbar using the > VAS 6342 - pressure control valve-3-  . Control lever starts to move. 
6. 5.6  Reduce the vacuum further to 165 - 175 mbar  and read oft the adjustment range on the dial gauge.

   > Setpoint value 8 mm +/- 1 mm 

7. 5.7  Reduce the vacuum further to 95 - 105 mbar  and read off the adjustment range on the dial gauge.

   > Setpoint value 3 mm +/- 1 mm 

8. 5.8  If necessary, set the adjustment range at the control rod with the dial gauge fitted and repeat the measurement process.

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   Vacuum pump and pressure sensor (diagram)

> Tightening torque 8 Nm (6 ftlb.) 

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Control rod and lock nuts

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Aligning the ball socket