Installing Electronic Adjuster

Information 

• There is no need to create a Vehicle Analysis Log (VAL). 

1. > VAS 5908 - Battery Charger, 90 A  must now be connected to the vehicle.
2. Have PIWIS Tester and  > 9954 - diagnostic cable  ready.
3. Install electronic adjuster -1-  .

   Screw on adjusting nut on the pull rod fully.

   Insert electronic adjuster and tighten screws.

   > Tightening torque 4.3 Nm (3.2 ftlb.) +/- 0.5 Nm (0.35 ftlb.) 

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   Electronic adjuster on turbocharger

4. Connect the PIWIS Tester  to the vehicle and switch on ignition.

   Select DME engine control unit  , then select the Maintenance/repairs  menu.

   Open the sub-menu Adjust electronic adjuster for turbocharger (bypass flap)  .

   Read the information about the preconditions and make sure to meet the preconditions! 

5. Move electronic adjuster into adjustment position using the PIWIS Tester  .

   The adjusting nut and lock nut must not be touching the kinematics lever! 

   > 9954 - Diagnostic cable  must now be connected to the electronic adjuster and the plug connection must be connected to the vehicle.

   Select the relevant turbocharger (left or right).

   Press F8=Start. The pull rod moves into the adjustment position.

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   Moving pull rod for electronic adjuster into adjustment position

   Information 

   • Press bypass flap closed with your hand as far as the kinematics mounting and hold it closed. 
6. Connect and adjust pull rod with kinematics lever. Get another person to help you with this work.

   Press bypass flap -1-  closed as far as the mounting with your hand -arrow- and hold it closed! 

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   Bypass flap

   Fit both nuts by hand.

   Tighten adjusting nut using > V.A.G 1783 - Torque wrench, 2-10 Nm (1.5-7.5 ftlb.)-2-  and counter at the lock nut -4-  . While tightening, get another person to counter at the kinematics lever using an open-ended wrench (a/f 16) -3-  to prevent strain.

   > Tightening torque 6 Nm 

   Press F8=Start on the Tester, then perform bypass flap adaptation  with F8=Start.

   When the adaptation is complete, switch off the ignition and disconnect the Tester.

   Release and disconnect diagnostic cable -5-  .

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   Adjusting electronic adjuster

   1	Electronic adjuster
   2	> V.A.G 1783 - Torque wrench, 2-10 Nm (1.5-7.5 ftlb.)  with open socket-wrench insert (a/f 10)
   3	Open-ended wrench, a/f 16
   4	Open-ended wrench, a/f 10
   5	Diagnostic cable 9954

7. Install new shield -1-  using lug-type clamps.

   Position shield with the closed seam at the upper edge -Arrows-  and press together at the bottom.

   Position lug-type clamps -2-  , hold clamps securely and secure using > V.A.G 1275A - Hose clip pliers  or > VAS 6199A - Clamping pliers  .

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   Shield on kinematics for electronic adjuster