Adjusting Bypass Flap Control Box

WARNING: This page is about a different variant/trim than selected.

Adjust the control rod in such a way that the actuating lever -1- is at the stop -2- .

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Actuating lever at stop
From this position, turn the threaded piece -2- by 1.5 turns anti-clockwise.
This makes the control rod longer.
1. 2.1 Tighten lock nuts -1 and 3- .
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Lock nuts on control box
Clamp a small clamping pliers -1- on the shaft of the ball socket -2- .
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.
Prepare measurement setup.
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
Adjust control box for bypass flap.
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 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)
Tighten lock nuts -1 and 3- .
> Tightening torque 8 Nm (6 ftlb.)

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Lock nuts on control box
Check that the ball socket is parallel to the actuating lever.

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Aligning the ball socket
Remove all tools.
Attach vacuum hose to the control box.