Skoda Workshop Service and Repair Manuals

Setting exhaust turbocharger pressure unit Special tools and workshop equipment required t  Universal dial gauge holder -MP 3-447 (VW 387)- t  Hand vacuum pump, e.g. -VAS 6213- t  Pressure control valve, e.g. -VAS 6342- t  Turbocharger tester , e.g. - V.A.G 1397 A- t  Dial gauge, e.g. -VAS 6341/1- t  Flat button, e.g. -VAS 6341/4- t  Hose clamps up to 25 mm -MP7-602 (3094)- t  Pliers for spring strap clamps t  Catch pan for workshop crane e.g. - VAS 6208- Work procedure –  Remove engine cover → Chapter. –  Remove the air filter housing → Chapter.

–  Release screws -arrows- and remove heat shield for exhaust turbocharger.

–  Release screws -2- and remove retaining clip -1-. –  Disconnect plug -3- from charge pressure sender -G31- with intake air temperature sender 2 -G299-. –  Unhook the hoses at the pressure pipe and open the cable guide. –  Press the retaining clips -arrows- towards the outside and pull the pressure pipe out towards the top. –  Then pull off the pressure pipe from the exhaust turbocharger.

–  Unscrew screw -4- and remove the crankcase ventilation hose from the exhaust turbocharger -arrow- and place it to the side.

–  Pinch off coolant hoses with hose clamps -MP7-602 (3094)- as shown in the figure. –  Release screws -1, 3, 4, 5-. –  Place a catch pan under the engine. –  Remove the coolant lines from the exhaust turbocharger and place them to the side.

–  Release screws -2- and -3-, remove retaining bracket. –  Remove catalytic converter → Chapter.

–  Remove the hose -2- from the exhaust turbocharger pressure unit.

–  Fit together the measurement and test equipment as shown in the figure and connect them at the connection “II” of the turbocharger tester -V.A.G 1397A- as well as on the exhaust turbocharger pressure unit. –  Connect the lever -1- at the pressure control valve - VAS 6342-. –  Position the sliding ring -2- of the hand vacuum pump -VAS 6213- in the -direction of arrow-.

–  Switch on the turbocharger tester -V.A.G 1397A- and position the sliding switch to position “II”. –  Operate the hand vacuum pump -VAS 6213- several times until a pressure of approx. 0.08 MPa (800 mbar) is reached.   Caution Risk of damage to the pressure box from excessive pressure. The pressure must not be greater than 0.08 MPa (800 mbar).

–  Ventilate the hand vacuum pump -VAS 6213--arrow A- so that the linkage of the charge pressure control can move freely in the exhaust turbocharger. –  Repeat the process 5 times.

–  Attach the universal dial gauge holder -VW 387- to the exhaust turbocharger as shown in the figure. –  Attach the dial gauge -VAS 6341/1- with the flat button -VAS 6341/4- at the universal dial gauge holder -VW 387-. –  At 0 MPa (0 bar) set the dial gauge -VAS 6341/1- to 1 mm preload. –  Set the readout of the dial gauge -VAS 6341/1- to “0”. –  Operate the hand vacuum pump -VAS 6213- several times until the turbocharger tester -V.A.G 1397A- indicates a pressure of 0.043 MPa (430 mbar). l  Nominal value on the dial gauge -VAS 6341/1-: 1 mm stroke.   Note

t  If the nominal value is not reached, loosen the counternut -4-. t  Lever off the circlip -2- and remove the threaded piece -1- from the bolt of the operating lever -3-. t  Unscrew the threaded piece from the actuator rod sufficiently until the nominal value is reached. Fit the threaded piece each time onto the bolt of the operating lever for checking. t  Secure the threaded piece with the circlip -2- onto the bolt of the operating lever and tighten the counternut -4-. Check the setting of the pressure unit –  At 0 MPa (0 bar) set the dial gauge -VAS 6341/1- to 1 mm preload. Measurement 1: –  Operate the hand vacuum pump -VAS 6213- several times until the turbocharger tester -V.A.G 1397A- indicates a pressure of 0.075...0.080 MPa (750....800 mbar). –  Release the pressure via the pressure control valve -VAS 6342- to 0.042 MPa (420 mbar). –  Read off stroke on the dial gauge -VAS 6341/1- and note. –  Release the pressure via the pressure control valve -VAS 6342- to 0 MPa (0 bar). –  Operate the hand vacuum pump -VAS 6213- several times until the turbocharger tester -V.A.G 1397A- indicates a pressure of 0.042 MPa (420 mbar). –  Read off stroke on the dial gauge -VAS 6341/1- and note. –  Calculate the mean value, to do so add the value “1” and “2” together and divide by 2. l  Specified value: 1 mm Measurement 2: –  Operate the hand vacuum pump -VAS 6213- several times until the turbocharger tester -V.A.G 1397A- indicates a pressure of 0.075...0.080 MPa (750....800 mbar). –  Release the pressure via the pressure control valve -VAS 6342- to 0.052 MPa (520 mbar). –  Read off stroke on the dial gauge -VAS 6341/1- and note. –  Release the pressure via the pressure control valve -VAS 6342- to 0 MPa (0 bar). –  Set the readout of the dial gauge -VAS 6341/1- to “0”. –  Operate the hand vacuum pump -VAS 6213- several times until the turbocharger tester -V.A.G 1397A- indicates a pressure of 0.052 MPa (520 mbar). –  Read off stroke on the dial gauge -VAS 6341/1- and note. –  Calculate the mean value, to do so add the value “1” and “2” together and divide by 2. l  Specified value: 5 mm –  If the nominal values are not reached, repeat setting. Installation occurs in reverse order for removal, while paying attention to the following: t  Tightening torques: → Chapter t  Tightening torque of heat shield for exhaust turbocharger: 8 Nm –  Install catalytic converter → Chapter. –  Inspect coolant level, if necessary top up cooling system and bleed → Chapter.