Turbocharger Vacuum Diaphragm, Replacing: Installing

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

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-- 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

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-- 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 PumpVAS6213 in position -A- for "vacuum".

Fig 3: Adjusting Hand Vacuum Pump Slide Ring

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-- Connect the Hand Vacuum Pump VAS6213 to the vacuum diaphragm -arrow-.

Fig 4: Identifying Hand Vacuum Pump

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CAUTION:

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

The vacuum should never be greater than 800 mbar.

Adjusting the Voltage Value, Refer to the information below.

-- Push the Han Vacuum Pump VAS6213 until the pressure gauge shows a vacuum between 650 to 700 mbar.

Version 1:

-- Slide the vacuum diaphragm in the direction of the -arrow-, until the voltage value shows from 0.75±0.02vol, refer to Vehicle Diagnostic Tester.

-- Tighten the bolts -1- to 10 Nm.

Fig 5: Identifying Bolts

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Version 2:

Fig 6: Identifying Bolts

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-- Slide the vacuum diaphragm in the direction of the -arrow-, until the voltage value shows from 0.75±0.02 volt, refer to Vehicle Diagnostic Tester.

-- Tighten the bolts -1- to 10 Nm.

-- Slide the slider ring -1- on the Hand Vacuum Pump VAS6213 in position -B- to vent the vacuum diaphragm until it reaches ambient temperature.

Fig 7: Adjusting Hand Vacuum Pump Slide Ring

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Check the Voltage Value

-- Set the slide ring -1- on the Hand Vacuum PumpVAS6213 in position -A- for "vacuum".

-- Push the Han Vacuum Pump VAS6213 until the pressure gauge shows a vacuum between 650 to 700 mbar.

-- The voltage value should show between 0.75±0.02volts, refer to Vehicle Diagnostic Tester

Voltage Value Not OK.

NOTE:

The illustration shows version 1.

-- Loosen the bolts -1-.

-- Adjusting the voltage value, refer to Installing

Voltage Value OK.

-- Seal the bolts with sealing wax from the repair kit.

-- Install the engine cover, refer to ENGINE COVER .

-- Start the engine and erase the DTC memory, refer to Vehicle Diagnostic Tester.

Fig 8: Identifying Bolts

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