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)
• Flat Pickup (VAS 6341/4)
• Dial Gauge 0-30 mm (VAS 6341/1)
• Dial Gauge Extension, 30 mm (VAS 6341/3)
Adjusting
• It is necessary to adjust the diaphragm only if it has been removed.
• For the correct tightening specifications => [ Part IV ] Turbocharger Overview
- Pre-adjust bypass flap - 1 - via nut - arrow - so flap can still just be turned by hand.
- Secure (VW 387) on turbocharger - arrow -.
• The mm specifications apply to the value read out (includes 1 mm pre-load).
• The (VAS 6341/1) and (VAS 6341/3) must align with the linkage on the diaphragm.
- Secure (VAS 6341/1) with (VAS 6341/3) and (VAS 6341/4) to (VW 387).
- Set the (VAS 6341/1) to 1 mm pretension.
- Rotate (VAS 6341/1) display to 0.
- Check dial gauge for ease of movement.
- Turn the nut - 1 - approximately 7 turns in direction of - arrow -.
- Turn the nut - 2 - in direction of - arrow - until the dial gauge shows 7 mm.
- Tighten the nut - 1 - hand-tight.
- Set the (VAS 6341/1) to 1 mm pretension.
- Rotate (VAS 6341/1) display to 0.
- Connect (VAS 6213) , (V.A.G 1397A) to connection II and (VAS 6342) as depicted in the illustration.
- Switch on (V.A.G 1397A) and adjust slide switch to position II.
- Close (VAS 6342) on lever - 1 -.
- Adjust slide ring - 1 - on (VAS 6213) to - B - position for "Pressure".
• 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.
• If 460 +/- 5 mbar is exceeded, then the measuring must be started again from the beginning.
- 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).
• If 460 +/- 5 mbar is not reached, then the measuring must be started again from the beginning.
- Read and make a not of the value on (VAS 6341/1).
- Add value 1 and 2 and divide by 2.
- The result (mean value) must be 5 +/- 0.5 mm.
- If the value is greater, then lower the pressure to 0 bar, loosen the nut - 1 - and turn the nut - 2 - a half a turn and then tighten the nut - 1 - hand-tight.
- Set the (VAS 6341/1) to 1 mm pretension.
- Turn the (VAS 6341/1) display to 0 and repeat the measurement.
- If the average value is 5 +/- 0.5 mm, then tighten the lock nut and repeat the measurement.
- If the average value is 5 +/- 0.5 mm, then secure the nuts with sealing wax. Sealing wax, refer to the Parts Catalog.
- Secure the new securing plate - 1 - over vacuum diaphragm linkage.
