Turbocharger Vacuum Diaphragm, Adjusting

WARNING: This page is about a different car, the 2008 Volkswagen Jetta, 2008 Volkswagen GLI, 2007 Volkswagen Jetta, and 2006 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Dial gauge holder VW 387
Hand vacuum pump VAS 6213
Pressure control valve VAS 6342
Turbocharger tester VAG 1397A
Dial gauge (0-30 mm) VAS 6341/1
Dial gauge extension (30 mm) VAS 6341/3
Flat pickup VAS 6341/4

NOTE:

The vacuum diaphragm must be adjusted only if the linkage was loosened.

Adjustment is performed only with turbocharger removed.

-- Disconnect the hose -arrow- from the vacuum diaphragm.

Fig 1: Disconnecting Hose From Vacuum Diaphragm At Turbocharger

GWWA21-10121

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clip above the linkage.

-- Loosen the lock nut -2-.

Fig 2: Identifying Lock Nut, Turbocharger, Vacuum Diaphragm

GWWA21-10124

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Pre-adjust the bypass flap -1- above the linkage for the vacuum diaphragm -arrow- so that the bypass flap can still just be turned by hand.

Fig 3: Pre-Adjusting Bypass Flap Above Linkage Of Vacuum Diaphragm

GWWA21-10122

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Tighten the lock nut by hand.

-- Connect the VAS 6213, VAG 1397A to connection II and the VAS 6342 as shown in the illustration.

Fig 4: Connecting Hand Vacuum Pump VAS 6213, Turbocharger Tester V.A.G 1397A To Connection II And Pressure Regulator Valve VAS 6342

GWWA21-10120

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Close the VAS 6342 at the lever -1-.

-- Set the slide ring -1- on the VAS 6213 to position -B- for "pressure".

Fig 5: Identifying Slide Ring On Hand Vacuum Pump VAS 6213 Set To Position For "Pressure"

GWWN24-10282

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Switch on the VAG 1397A and set the slider switch to position II.

-- Secure the VW 387 on turbocharger -arrow-.

Fig 6: Securing Dial Gauge VAS 6341/1 With 30 mm Extension VAS 6341/3 And Level Tester VAS 6341/4 On Universal Dial Gauge Holder VW 387

GWWA21-10123

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Secure the VAS 6341/1 with the VAS 6341/3 and the VAS 6341/4 onto the VW 387.

-- Set the VAS 6341/1 to 0 bar with 1 mm preload.

-- Rotate the indicator on the VAS 6341/1 to 0.

-- Check the dial indicator for ease of movement.

-- Operate the VAS 6213 until the VAG 1397A displays 350 ± 5 mbar.

-- The VAS 6341/1 must display 4.1 mm to 4.3 mm, otherwise rotate the vacuum diaphragm linkage until the value is displayed.

-- Tighten the lock nut by hand.

-- Repeat the measurement.

NOTE:

The mm specifications apply to the value read out (includes 1 mm preload).

-- Release the pressure via the VAS 6342 to 0 mbar.

-- Set the VAS 6341/1 to 0.

NOTE:

The following measurements must be performed in one sequence. In the meantime, pressure must not dissipate to 0.

-- Operate the VAS 6213 until the VAG 1397A displays 350 ± 5 mbar.

-- Read and make a note of the value on the VAS 6341/1.

-- Operate the VAS 6213 until the VAG 1397A displays 650 to 700 mbar.

-- Release the pressure via the VAS 6342 to 350 ± 5 mbar.

-- Read and make a note of the value on the VAS 6341/1.

-- Add value 1 and 2 and divide by 2.

The result (mean value) must be 5 ± 0.25 mm.

If the result (mean value) is not 5 ± 0.25 mm:

-- Correct the adjustment, tighten the lock nut hand tight and repeat the measurement.

If the result (mean value) is 5 ± 0.25 mm:

-- Tighten the lock nut and secure it with sealing wax.

Tightening specification: 5 Nm.

-- Secure the securing plate above the vacuum diaphragm linkage.

Make sure the securing plate is locked in place.