SEAT Workshop Service and Repair Manuals

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

Special tools and workshop equipment required

t	Universal dial gauge support -VW 387-, see equivalent → Anchor

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

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

t	Turbocharger tester -V.A.G 1397A-, see equivalent → Anchor

t	Gauge set (4 element set) -VAS 6341-, see equivalent → Anchor

t	Torque wrench -V.A.G 1783-, see equivalent → Anchor.

t  Pin tool e/c 10 -V.A.G 1783/1-, see equivalent → Anchor

t  Hose clamps -3094-, see equivalent → Anchor

Operation process –  Disengage coolant hose -1- at engine cover panel. –  Pull out the dipstick.-2-. –  Unscrew bolts -arrows- and remove engine cover panel. –  Remove air cleaner housing → Chapter.

–  Unscrew the fastening bolts -arrows- and remove the heat protection plate from the turbocharger.

–  Unscrew bolts -2- and detach retaining bracket -1-. –  Unplug electrical connector -3- at charge pressure sender -G31-. –  Release retainers -arrows- and detach air pipe first from throttle valve module -J338- and then from turbocharger. –  Move hoses on air pipe clear.

–  Remove bolt -4-, detach crankcase breather hose from turbocharger -arrow- and move clear to one side.   Note Ignore positions -1, 2 and 3-.

–  Choke coolant hoses with the hose clamps -3094-, as shown in figure. –  Remove bolts -1, 3, 4, 5-. –  Disconnect the coolant pipes from the turbocharger and set to one side.   Note Ignore position -2-.

–  Unscrew bolts -2- and -3- and remove fastening plate.   Note Ignore positions -1- and -4-. –  Remove the primary catalytic converter with exhaust pipe → Chapter.

–  Remove the hose -2- of the pressure capsule for turbocharger.   Note Ignore position -1-.

–  Close the lever -1- in the pressure regulating valve -VAS 6342-. –  Interconnect measurement and test equipment, as shown in the figure, and connect to terminal „II“ of the turbocharger tester -V.A.G 1397A- and the turbocharger pressure capsule. –  Move sliding ring -2- of the manual vacuum pump -VAS 6213- to the limit in the -direction of the arrow-.

–  Activate the turbocharger tester -V.A.G 1397A- and move the sliding switch to position „II“. –  Activate the manual vacuum pump -VAS 6213- several times until a pressure of 800 mbar is obtained.   Caution There is a risk of damage to the pressure capsule due to excess pressure. Pressure must not exceed 800 Millibar!

–  Ventilate the manual vacuum pump -VAS 6213--arrow A- to allow adjustment linkage of the supercharger pressure control in the turbocharger to move freely. –  Repeat procedure 5 times.

–  Fix the dial gauge -VAS 6341/1- with the flat contact -VAS 6341/4- to the universal dial holder -VW 387-. –  Fix the universal dial holder -VW 387- on the turbocharger, as shown in the figure. –  At 0 bar, tense the gauge -VAS 6341/1- to 1 mm. –  Position the indicator of the dial gauge -VAS 6341/1- to „0“. –  Activate the manual vacuum pump -VAS 6213- several times until a pressure of 385 mbar is shown on the turbocharger dial gauge -V.A.G 1397A-. l  Specification of the Gauge set -VAS 6341/1-: Range 1 mm   Note

t  If the theoretical value is not obtained, loosen the lock nut -4-. t  Lever off safety washer -2-, then remove threaded part -1- on the control level rod -3-. t  Turn the threaded part on the control rod until the theoretical value is reached. To check, connect the threaded part to the control lever rod. t  Secure the threaded part with the safety washer -2- on the control lever rod and tighten the counter nut -4-. Check the setting of the pressure capsule –  At 0 bar, tense the gauge -VAS 6341/1- to 1 mm. Measurement 1: –  Activate the manual vacuum pump -VAS 6213- several times until a pressure of 750 ... 800 mbar is shown on the turbocharger dial gauge -V.A.G 1397A-. –  Release pressure in the pressure control valve -VAS 6342- to 375 mbar. –  Read and note the value indicated by the gauge -VAS 6341/1-. –  Release pressure in the pressure control valve -VAS 6342- to 0 mbar. –  Activate the manual vacuum pump -VAS 6213- several times until a pressure of 375 mbar is shown on the turbocharger dial gauge -V.A.G 1397A-. –  Read and note the value indicated by the gauge -VAS 6341/1-. –  Calculate average value; by adding values „1“ and „2“ and dividing by 2. Specification: 1 mm Measurement 2: –  Activate the manual vacuum pump -VAS 6213- several times until a pressure of 750 ... 800 mbar is shown on the turbocharger dial gauge -V.A.G 1397A-. –  Release pressure in the pressure control valve -VAS 6342- to 475 mbar. –  Read and note the value indicated by the gauge -VAS 6341/1-. –  Release pressure in the pressure control valve -VAS 6342- to 0 mbar. –  Set the dial gauge -VAS 6341/1- indicator to "0". –  Activate the manual vacuum pump -VAS 6213- several times until a pressure of 475 mbar is shown on the turbocharger dial gauge -V.A.G 1397A-. –  Read and note the value indicated by the gauge -VAS 6341/1-. –  Calculate average value; by adding values „1“ and „2“ and dividing by 2. Specification: 5 mm –  Repeat adjustment procedure if readings do not match specifications → Anchor. Assembling Tightening torques → Chapter Tightening torque of the heat protection plate for the exhaust gas turbocharger: 10 Nm Install in the reverse order to removal. –  Install air cleaner housing → Chapter. –  Mount the primary catalytic converter with exhaust pipe → Chapter.