Golf L4-1896cc 1.9L DSL Turbo (1Z) (1997)
Air Bypass Valve: Service and Repair
Engine Code 1Z
Special Tools, Testers And Auxiliary Items:
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VAG1331 torque wrench 5 to 50 Nm
Removing:
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Remove turbocharger.
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Unclip mounting clip -4-.
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Remove mounting bolts -2-.
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Remove wastegate -6-.
Installing:
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Install wastegate -6- on turbocharger and tighten.
Tightening torque: 10 Nm (7 ft lb).
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Install mounting bolts -2- using D6.
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Loosen lock nut -1- and operating rod -3-.
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Swing wastegate lever -5- toward turbocharger to stop, and hold.
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Adjust length of rod -3- so that rod eye will install easily on lever pin -5- (lever lies against stop with no play).
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Shorten operating rod 8 full turns from this position.
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Tighten lock nut -1-.
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Attach operating rod onto lever and install mounting clip -4-.
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Re-install turbocharger.