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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Lock nuts on control box

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

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Clamping pliers on control rod

Information 

The measurement setup is described for one side as an example.

1. 4.1 > VW387 - Dial gage holder  must be secured to the engine transport eyebolt -2-  .
2. 4.2 Align the > VAS 6079 - Dial gauge  in the > VW387 - Dial gage holder  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-regulating 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-regulating valve-3-  .

   Control lever starts to move. 

6. 5.6 Reduce the vacuum further to 170 - 230 mbar  and read off the adjustment range on the dial gauge.

   > Setpoint value 8 mm +/- 1 mm 

7. 5.7 Reduce the vacuum further to 100 - 170 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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Lock nuts on control box

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Aligning the ball socket