Turbocharger Vacuum Diaphragm, Replacing: Installing: Notes

WARNING: This page is about a different car, the 2015 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Use new bolts and new locking rings from the repair set.

Version 1:

Fig 1: Identifying Vacuum Hose, Locking Ring And Vacuum Diaphragm Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Engage the control rod on the adjusting lever.

-- Insert the vacuum diaphragm and install the bolts -1- by hand until stop.

NOTE: When removing and installing the circlip the force on the lever system is to be kept low. Pushing down the circlip for example with a large screwdriver can cause damage to the turbocharger.

-- Install circlip -4-.

-- Connect the connector -3- on the Charge Pressure Actuator Position Sensor - G581-.

Version 2:

Fig 2: Identifying Vacuum Hose, Vacuum Diaphragm And Locking Ring

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Engage the control rod on the adjusting lever.

-- Insert the vacuum diaphragm and install the bolts -3- by hand until stop.

NOTE: When removing and installing the circlip the force on the lever system is to be kept low. Pushing down the circlip for example with a large screwdriver can cause damage to the turbocharger.

-- Install circlip -4-.

-- Connect the connector -2- on the Charge Pressure Actuator Position Sensor - G581-.

Continuation for All Versions:

-- Adjust the vacuum diaphragm control rod, to do this measure the raw voltage.

-- To do so, refer to Vehicle Diagnostic Tester.

Guided functions
01 Adapting the electric actuator with feedback

-- Set the slide ring -1- on the Hand Vacuum Pump VAS 6213 in position -A- for "vacuum".

Fig 3: Adjusting Hand Vacuum Pump Slide Ring

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-- Connect the Hand Vacuum Pump VAS 6213 to the vacuum diaphragm -arrow-.

Fig 4: Identifying Hand Vacuum Pump

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

CAUTION: There is a risk of damaging the vacuum diaphragm due to a high vacuum.

The vacuum should never be greater than 800 mbar.