SEAT Workshop Service and Repair Manuals

Adjusting vacuum unit for turbocharger   Note The pressure capsule only has to be set when the rods have been released.

Consult the equivalence table for tools and equipment according to applicability among Seat / VW / Audi / Skoda → Chapter.

Special tools and workshop equipment required

t	Pressure regulating valve -VAS 6342-, see equivalent → Anchor

t	Gauge set -VAS 6341-, see equivalent → Anchor

t	Manual vacuum pump -VAS 6213-, see equivalent → Anchor

t	Turbocharger tester -VAG 1397A-, see equivalent → Anchor

t	Adjustment tool -VW 387-, please see Correspondence → Anchor

t	Pliers for spring-loaded band-type clamps -VAS 6340-, see equivalent → Anchor

Operation process –  Lift the engine cover by the positions -1- and push the cover forwards in the direction of the -arrow-.

–  Unscrew the screws -arrow- of the heat protection plate above the exhaust turbocharger. –  Open and close the lid of the expansion tank again for releasing the pressure in the cooling system. –  Drain coolant → Chapter   Note Remove the coolant hoses from the engine using the hose clip pliers -VAS 6340-.

–  Remove the connecting hose -1- and the coolant hose -3-. –  Remove bolts and securing nuts -4- from turbocharger.

–  Unscrew securing bolt -2- and remove upper coolant pipe.   Note The lower coolant pipe can only be removed after the main catalytic converter has been dismantled. –  Unscrew bolts -1- and remove pressure pipe.

–  Unscrew the securing bolts -arrows- and remove the engine soundproofing.. –  Remove the primary catalytic converter with exhaust pipe → Chapter.

–  Pull hose -arrow- from vacuum unit. Checking vacuum unit adjustment → Chapter. 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 the knurled nut a further two rotations. –  Tighten lock nut hand-tight.

–  Connect the manual vacuum pump -VAS 6213- and the turbocharger tester -VAG 1397A- to the connection -II- and on the pressure regulating valve -VAS 6342- as shown. –  Attach the pressure regulating valve -VAS 6342- to the lever -2-. –  Push sliding ring -1- on hand vacuum pump -VAS 6213- to pressure gauge in direction of -arrow-. –  Turn on the turbocharger tester -VAG 1397A- and push the sliding switch to position -II-.

–  Fix the adjustment tool -VW 387- to the exhaust turbocharger.   Note The dial gauge linkage and the vacuum unit linkage must align. –  Fix the gauge -VAS 6341/1- with the 30 mm extension -VAS 6341/3- and the flat pushbutton -VAS 6341/4- to the adjustment tool -VW 387-. –  With pressure at 0 bar, set dial gauge -VAS 6341/1- to 1 mm preload. –  Operate the manual vacuum pump -VAS 6213- several times until a pressure of approx. 800 mbar is displayed on the turbocharger tester -VAG 1397A-. –  Lower the pressure to 0 mbar with the pressure regulating valve -VAS 6342-. –  Repeat this procedure approx. 3-5 times.   Note This procedure is intended to prevent the vacuum unit bypass flap or linkage from jamming.   Note The figures in mm refer to the value checked (including pre-tension of 1 mm). –  Lower the pressure to 0 mbar with the pressure regulating valve -VAS 6342-. –  Set dial gauge -VAS 6341/1- to 0.   Note t  The following measurements must be performed in continuous sequence. Do not allow the pressure to drop to 0 between measurements. t  Do not knock against linkage throughout the entire measurement procedure. –  Operate the hand vacuum pump -VAS 6213- until turbocharger tester -VAG 1397A- indicates 500 +/- 5 mbar. –  Read off and note value indicated on dial gauge -VAS 6341/1-. –  Operate the hand vacuum pump -VAS 6213- until turbocharger tester -VAG 1397A- indicates 800 +/- 5 mbar. –  Lower the pressure to 500 +/- 5 mbar with the pressure regulating valve -VAS 6342-. –  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 sequence; note the following: t  Renew seals, gaskets and self-locking nuts. t  Hose connections and hoses for charge air system must be free from oil and grease before fitting. t  Secure all hose connections with hose clips which conform to production standard. t  If renewed, place oil seal in groove of charge air hose. Ensure seal is correctly seated in groove. t  Lightly moisten seal with engine oil.

t  Bring retaining clip to release position -arrow-. t  When installing air pipes with plug-in connector, ensure that securing clip -arrow- audibly engages into retaining lug -A-.   Caution The screw-type clips on the charge air pipes must be tightened to 5.5 Nm. If the torque is too low or too high, the charge air hose may slip off the charge air pipe during vehicle operation. Exhaust turbocharger - assembly overview → Chapter. Assembly overview - charge air system → Chapter. Catalytic converter and attaching parts - Assembly overview → Chapter Continue installation following reverse order for removing.