Turbocharger: Adjustments
Turbocharger Vacuum Diaphragm, Adjusting
Turbocharger removed
Special tools, testers and auxiliary items required
• Dial Gauge Holder (VW 387)
• Hand Vacuum Pump (VAS 6213)
• Pressure Control Valve (VAS 6342)
• Turbocharger Tester (V.A.G 1397A)
• Dial Gauge Set, 4-part (VAS 6341)
• Torque Wrench (V.A.G 1783)
• Open End Spanner Insert AF 10 (V.A.G 1783/1)
Adjusting
• For the correct tightening specifications, refer to => [ Part IV ] Turbocharger Overview.
- Remove hose - arrow - from vacuum diaphragm on turbocharger.
- Loosen the clamp over the linkage on the turbocharger.
- Loosen lock nut - 2 -.
- Adjust the bypass flap - 1 - using the knurled nut - arrow - so that the flap can still just be turned by hand.
- Install the lock nut hand-tight.
- Connect the (VAS 6213) and the (VAS 6342) to the vacuum diaphragm and to connection II on the (V.A.G 1397A) , as illustrated.
- Close (VAS 6342) on lever - 1 -.
- Adjust slide ring - 1 - on (VAS 6213) to - B - position for "Pressure".
- Switch on (V.A.G 1397A) and adjust slide switch to position II.
- Secure (VW 387) on turbocharger - arrow -.
• The mm specifications apply to the value read out (includes 1 mm pre-load).
- Secure dial gauge 0-30 mm (VAS 6341/1) with dial gauge extension, 30 mm (VAS 6341/3) and flat pickup (VAS 6341/4) to (VW 387).
- Set (VAS 6341/1) to 1 mm tension at 0 bar.
- Rotate (VAS 6341/1) display to 0.
- Check dial gauge for ease of movement.
- Run the (VAS 6213) until the (V.A.G 1397A) shows 460 +/- 5 mbar.
- 4.1 mm to 4.3 mm must appear in the dial gauge; if not, turn the knurled nut until the value is displayed.
- Tighten the lock nut hand-tight.
- Repeat measurement.
- Reduce pressure to 0 mbar via (VAS 6342).
- Set (VAS 6341/1) to 0.
• The following measurements must be performed in one sequence. In the meantime, pressure must not dissipate to 0.
- Run the (VAS 6213) until the (V.A.G 1397A) shows 460 +/- 5 mbar.
- Read and make a note of the value on (VAS 6341/1).
- Operate (VAS 6213) until (V.A.G 1397A) displays 650 mbar to 700 mbar.
- Reduce the pressure to 460 +/- 5 mbar using the (VAS 6342).
- Read and make a note of the value on (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 lock nut hand-tight and repeat the measurement.
- If the result (average) is 5 +/- 0.25 mm, tighten the lock nut and secure with sealing wax. Sealing wax, refer to the Electronic Parts Catalog (ETKA).
- Secure securing plate - 1 - over vacuum diaphragm linkage.
