1.4 TSI engine (EA111) · Turbocharging/supercharging · Exhaust turbocharger

Adjusting vacuum unit for turbocharger

Special tools and workshop equipment required

  • Pressure regulating valve - VAS 6342-
  • Dial gauge set, 4-part - VAS 6341-
  • Hand operated vacuum pump - VAS 6213-
  • Turbocharger tester - V.A.G 1397A-
  • Universal dial gauge holder - VW 387-
  • Dial gauge extension, 30 mm - VAS 6341/3- (not shown)
  • Flat pickup - VAS 6341/4- (not shown)

Procedure

  • Lift engine cover panel at points -1- and pull it forwards in direction of -arrow-.
  • Unbolt heat shield over turbocharger -arrows-.
  • Open and close expansion tank cap to release pressure in cooling system.
  • Now drain coolant.
  • Pull off connecting hoses -1- and coolant hoses -3-.
  • Remove bolts and securing nuts -4- from turbocharger.
  • Unscrew securing bolt -2- and remove upper coolant pipe.
  • Unscrew bolts -1- and remove pressure pipe.
  • Depending on vehicle equipment, remove noise insulation or skid plate ⇒ General body repairs, exterior; Rep. gr. 50; Removing and installing noise insulation or skid plate.
  • Remove wiring for Lambda probe after catalytic converter - G130- and for alternator from cable guides -arrows-.
  • Pull connector off Lambda probe after catalytic converter - G130- and remove.
  • Open hose clip -3- and remove charge air pipe -2-.
  • Unbolt exhaust pipe from catalytic converter -arrows-.
  • Remove catalytic converter downwards.
  • Pull hose -arrow- from vacuum unit on turbocharger.

Checking vacuum unit adjustment ⇒ 1.3 Checking vacuum unit for turbocharger.

Continuation if the vacuum unit has been renewed or the linkage loosened

  • Remove sealing paint from lock nut -2-.
  • Pull off retaining clip -1- and loosen lock nut -2- on vacuum unit linkage.
  • Pre-adjust bypass flap -2- on vacuum unit linkage -1- via knurled screw, so that bypass flap can just be turned by hand.
  • Turn knurled nut -1- 2 turns further.
  • Tighten lock nut hand-tight.
  • Connect hand vacuum pump - VAS 6213-, turbocharger tester - V.A.G 1397A- to connection -II- and pressure control valve - VAS 6342- as shown in illustration.
  • Close pressure control valve - VAS 6342- at lever -2-.
  • Push sliding ring -1- on hand vacuum pump - VAS 6213- to pressure gauge in direction of -arrow-.
  • Switch on turbocharger tester - V.A.G 1397A- and set sliding switch to position -II-.
  • Secure universal dial gauge bracket - VW 387- to turbocharger.
  • Secure dial gauge - VAS 6341/1- with dial gauge extension, 30 mm - VAS 6341/3- and flat pickup - VAS 6341/4- to universal dial gauge bracket - VW 387-.
  • With pressure at 0 bar, set dial gauge - VAS 6341/1- to 1 mm preload.
  • Operate hand vacuum pump - VAS 6213- until a pressure of 800 mbar is displayed on turbocharger tester - V.A.G 1397A-.
  • Vent system via pressure control valve - VAS 6342- so that pressure reading drops to 0 mbar.
  • Repeat this procedure approx. 3-5 times.
  • Vent system via pressure control valve - VAS 6342- so that pressure reading drops to 0 mbar.
  • Set dial gauge - VAS 6341/1- to 0.
  • Operate hand vacuum pump - VAS 6213- until turbocharger tester - V.A.G 1397A- indicates 500 +/- 5 mbar.
  • Read off and note value indicated on dial gauge - VAS 6341/1-.
  • Operate hand vacuum pump - VAS 6213- until turbocharger tester - V.A.G 1397A- indicates 800 +/- 5 mbar.
  • Vent system via pressure control valve - VAS 6342- so that pressure reading drops to 500 +/- 5 mbar.
  • Read off and note value indicated on dial gauge - VAS 6341/1-.
  • Add values 1 and 2 together and divide by 2.
  • The result (mean value) should be 5.5 +/- 0.25 mm.
  • Correct setting if the result (average) is not 5.5 +/- 0.25 mm, tighten lock nut hand-tight and repeat measurement.
  • If the result (mean value) is 5.5 +/- 0.25 mm, tighten the lock nut to 9 Nm and secure with sealing paint.
  • Secure retaining clip to vacuum unit linkage.

Installation is carried out in the reverse order. When installing, note the following:

  • Renew seals, gaskets and self-locking nuts.
  • Hose connections and hoses for charge air system must be free of oil and grease before assembly.
  • Secure all hose connections with hose clips which conform to production standard.
  • If renewed, place seal in groove of charge air hose. Ensure seal is correctly seated in groove.
  • Lightly moisten seal with engine oil.
  • Bring retaining clip to release position -arrow-.
  • When installing air pipes with plug-in connector, ensure that securing clip -arrow- audibly engages into retaining lug -A-.

Assembly overview - turbocharger ⇒ 1.1 Assembly overview - turbocharger.

Assembly overview - charge air system ⇒ 3 Charge air system

Removing and installing parts of exhaust system ⇒ 26 – Exhaust system