Volkswagen Workshop Service and Repair Manuals

Changing and adjusting vacuum unit on turbocharger - only vehicles with engine code: BLS from model year 2008

Special tools and workshop equipment required

t	Hand vacuum pump -VAS 6213-

t	Turbocharger tester -V.A.G 1397A-

t	Pressure regulating valve -VAS 6342-

t	Ring spanner -T10423-

t	Allen key, long reach -T10454-

t	14 mm open-end spanner -T10461-

Caution The special tools indicated, in particular the socket inset, -T10454- is designed solely for use according to the following work instructions and must not be used for other threaded connections. There is a danger of deformation if high torques are applied.   Note A replacement parts kit is available when changing the vacuum unit → Electronic parts catalogue. Removing Golf Plus, Touran –  To change vacuum unit, remove and install turbocharger → Chapter.. Continuation Golf , Passat –  Remove engine cover.

–  Pull cover off air duct (release clips on sides) -arrows-.

–  Unclip lower air duct -2- by releasing retaining clips on left and right -arrow A-. –  Unclip air duct at mountings -3-. –  Swing air duct downwards and slightly to rear for this. –  Detach air pipe -1- from lower air duct -arrow B-.

–  Disconnect electrical connector -1- from air mass meter -G70-. –  Pull off vent hose -3- and also air duct hose -2-. –  Remove bolt -4- and remove air filter housing.

–  Detach hose -2- from crankcase breather. –  Lay aside ventilation hose -4- and vacuum hoses -1- at air hose. –  Unscrew bolt -3-. –  Swing air duct hose to rear and pull off of turbocharger. –  Seal opening in turbocharger with the plug from the spare-parts kit. –  Pull off vacuum hose on turbocharger.

–  Depending on version, unscrew nut -arrow- where the oil supply line/vacuum line is connected to the cylinder head.   Caution When detaching the oil supply line, counterhold the connection. Risk of damage as a consequence!

–  Counterhold union with 14 mm open-jaw wrench -T10461- and unscrew oil supply line -arrow- on turbocharger. –  Seal oil supply opening in turbocharger with the plug from the spare-parts kit.

–  Counterhold lock nut -B- with ring spanner -T10423- and unscrew securing nut -A- from the control rod using socket inset -T10454-.

–  Remove bolt -1-, then bolt -2- and remove vacuum unit -A-. Installing

–  Colour mark vacuum unit and control rods -as shown-.   Note The colour marks show that the control rods are adjusted correctly, after tightening. Adjustments should then be made as necessary.   Caution Only use new bolts and nuts from the spare-parts kit! –  If necessary, remove lower securing nut of the control rod from the new vacuum unit. –  Screw locknut by hand onto the control rod as far as possible in the direction of the vacuum unit. –  Push control rod through the adjusting lever on turbocharger, fit vacuum unit -A- and lock.

–  Fit bolts -1- and -2- from repair kit. –  Tighten bolts -1- and -2- to 8 Nm.

–  Switch on turbocharger tester -V.A.G 1397A- and set sliding switch to position „I“. –  Subtract 600 mbar from atmospheric pressure displayed and note value. (Value 1) –  Subtract 650 mbar from atmospheric pressure displayed and note value. (Value 2)

–  Connect test and measuring instruments together as illustrated and connect to connection „I“-arrow- of turbocharger tester -V.A.G 1397A- and to turbocharger vacuum unit. –  Close lever -1- on pressure regulating valve -VAS 6342-.

–  Move slide ring -1- on hand vacuum pump -VAS 6213- to position -A- for „vacuum“.   Caution Excessive pressure may damage the vacuum unit. The pressure must not fall below the read atmospheric pressure minus 800 mbar.   Note t  An accuracy of +/- 20 mbar is acceptable when setting value 2. t  Make sure that the turbocharger adjusting lever moves easily on the control rod. –  Operate hand vacuum pump -VAS 6213- several times until noted value 2 is attained on turbocharger tester -V.A.G 1397A-.

–  Open pressure regulating valve-1- until value 1 is set exactly.

–  Screw nut -A- up a couple of threads on control rod.

–  Hold adjusting lever -1- on »stop« of adjustment screw -2- by hand.   Note

t  During next procedure, ensure adjusting lever -1- remains against stop screw -2- and is not already contacting the securing nut -A-. t  Screw securing nut -A- back if this occurs.

–  Screw control rod lock nut -B- down slowly, by hand, until it contacts the adjusting lever -1-, do not turn further. –  Screw securing nut -A- up on control rod until it lies against adjusting lever.   Note Ensure control rod does not move while tightening securing nut -A-. –  Counterhold lock nut -B- with ring spanner -T10423- and tighten securing nut -A- using socket inset -T10454-.

–  Check colour marks on control rod, the must align -as shown-.

–  Release vacuum, move slide ring -1- on hand vacuum pump to position -B- for this, then move slide ring back to position -A- again.   Note There very little space between cylinder head and turbocharger. Ensure you are aware of where the feeler gauge (0.05 mm) is positioned.

–  The feeler gauge (0.05 mm) must be positioned between adjusting lever and adjustment screw, as shown   Note The feeler gauge (0.05 mm) has a part number and must be ordered from the → Electronic parts catalogue. –  Operate the hand vacuum pump -VAS 6213- until the feeler gauge (0.05 mm) is pinched between adjusting lever and adjustment screw. Now the »noted value 1« +/- 20 mbar should appear on the turbocharger tester -V.A.G 1397A-. Value OK.

–  Seal connection between control rod and securing nut with sealing paint from the spare-parts kit. –  Press locking plate by hand onto the control rod and turn 90° in the -direction of the arrow-. Value not OK. Repeat adjustment procedure again. Continuation

14 mm tool for counterholding connection piece of oil supply line t  A = 110 mm t  B = 25 mm

–  Counterhold connection piece and tighten oil supply line -arrow- on turbocharger.

–  Depending on version, reconnect oil supply line/vacuum line to the cylinder head and tighten nut -arrow-. Golf Plus, Touran –  Install plenum chamber bulkhead → General body repairs, exterior; Rep. gr.50. All other vehicles continued –  Complete the engine. –  Start motor and delete event memory → Vehicle diagnostic tester.