ATU Audi Technical Updates

A3 2.0 TDI Turbo Charger Vacuum Unit

Contents: Technical actions

Engine
No.

Event
1

Title orAudi
name,
division,
ATU,
8/2010Date

03/10

Topic

Type/model

Replacing turbocharger a vacuum unit

A3 and TT

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Complaint and problem description

Glow plug filament flashes
The following entries may appear in the fault memory for the engine control unit:
- P0299 Charge pressure control, "lower than" control limit
- P2563 Position sender for charge pressure positioner, "implausible signal

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Necessary special tools

Create tools yourself - SW 14 to counterhold the connection for the oil supply line:
A = 110 mm
B = 25 mm

Testing and measuring equipment

- Hand vacuum pump "VAS 6213"
- Vehicle diagnostic tester

Title orAudi
name,
division,
ATU,
8/2010Date

Caution:

The specified special tools, in particular the

plug-in tool T10422, are designed solely for
use as described in the following work
procedure and may not be used for other
screw connections, as this runs the risk of
deformation caused by using higher torques.

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Note:
A replacement part kit "03L198716" is available for changing the control capsule with charge pressure
positioner - G581
See electronic parts catalogue (ETKA)

Removal:

- Remove the air cleaner housing with air mass meter and connecting pipe
- Detach connecting pipe "1" for crankcase breather from the
cylinder head cover by pressing the release tabs.
- Uncover the vacuum hoses see arrows
- Unscrew screw "2" (undetachable), swing air pipe
back with suction pipe and
detach from the turbocharger.
Close the opening on the turbocharger using the
sealing cap in the replacement part kit.
- Remove the thermal insulating sleeve surrounding electrical connector "1".
- Detach electrical connector "1" on the position sender for charge
pressure positioner "G581".
- Disconnect vacuum hose "2" from the vacuum unit on the
turbocharger.
5

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Removal:
- Depending on the design, unscrew and remove securing nut "arrow"
for the connection oil supply line/vacuum line on the cylinder head

Note!
When loosening the oil supply line, always counterhold the connections.
Risk of damage!
- Counterhold connections with custom-built open-end spanner
and unscrew and remove oil supply line "arrow" on the turbocharger.

A = 110 mm
B = 25 mm
Seal the oil supply hole on the turbocharger with the
plugs from the replacement part kit.

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Removal:
- Counterhold lock nut "B" with ring spanner "T10423"
and unscrew and remove securing nut "A" from the control rod
using plug-in tool "T10422".

- Loosen securing bolts on the vacuum unit "arrow"

and remove vacuum unit "A".

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Installation:
Note!
Only use new screws and nuts from the replacement part kit!
- Remove lower (if present) securing nuts from the control rod
on the new vacuum unit
- Manually turn locking nut on the control rod as far as it will go
in the direction of the vacuum unit
- Guide control rod through the control lever on the turbocharger,
position vacuum unit "A" and attach the securing bolts
- Tighten securing boltsarrows to 8 Nm
Note:
Ensure that the guide moves smoothly on the control rod.

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Installation:
- Remove protective cap, place the oil supply line "arrow" on the
turbocharger and tighten to 22 Nm.

- Plug in connector "2" on the position sender for charge pressure

positioner -G581- and close heat shield mat

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Connect vehicle diagnostic tester and set the vacuum unit control rod:
Select mode:
- Press the button for vehicle self-diagnosis on the display
Select vehicle system:
- Press the button 01 Engine electronics on the display
- The display shows the control unit identification and coding
for the engine control unit.
Select diagnostic function:
- Press the button "011" measured values on the display
- Using the number block enter the measured value block "120"
and confirm the entry by pressing the "Q" key.
- Connect hand vacuum pump "VAS 6213" to the vacuum unit
- While monitoring the lowest value of the measured value block,
set a voltage of 0.760 V by creating a vacuum
During the subsequent setting procedure for the control rod, keep the vacuum and therefore the
voltage of 0.760 V constant.

10

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Set the vacuum unit control rod:

- Twist the lock nut "B" down the control rod slowly by hand.
Control lever is at the lowest "stop"
- Counterhold lock nut "B" and twist securing nut "A" on
the control rod against the control lever. Using ring
spanner "T10423", screw on loosely
- Relieve the vacuum in the control unit.
- Monitor the lowest value in the measured block value;
this must settle at a value of 3.303.90 V when depressurised.
- Position the plug-in tool "T10422", counterhold lock nut "B" using ring
spanner "T10423" and tighten securing nut "A".
tighten.
Note!
Create a vacuum of 750 50 mbar on the vacuum unit to ensure that the control lever is at the
"stop". A voltage of 0.760 V must be generated.

11

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Set the vacuum unit control rod:

Voltage value OK
- Press the lock washer onto the control rod by hand
and twist it by 90 in the direction of the arrow.
- Seal the control rod/securing nut connection with sealing wax
paint from the replacement part kit.
Voltage value not OK
- Counterhold lock nut "B" and loosen securing nut "A" on
the control rod; twist lock
nut "B" to correct the value.
- Counterhold lock nut "B" and turn securing nut "A" in the opposite
direction and tighten with plug-in tool "T10422".
- Press the lock washer onto the control rod by hand and
twist it by 90 in the direction of the arrow.
- Seal the control rod/securing nut connection with sealing wax
paint from the replacement part kit.

12

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed

Set the vacuum unit control rod:

- Depending on the design, unscrew and place securing nut "arrow"
on the connection oil supply line/vacuum line on the cylinder head and
tighten. Remove the sealing cap on the turbocharger
- Finish work on the engine
- Start engine and delete fault memory connect vehicle diagnostic,
measuring and information "VAS 5051".

- Check setting as follows:

Select basic diagnostic function setting:

- Press the button "006" Basic setting on the display
- Using the number block enter the measured value block "120"
and confirm the entry by pressing the "Q" key
- Press the "Activate" button on the lower half of the screen.
- Monitor the values on the lower screen window; must fluctuate
between 0.650.85 V and 3.303.90 V (vacuum unit will
move alternately to both end stops).
Voltage values OK exit basic setting!
13

Title orAudi
name,
division,
ATU,
8/2010Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed
Measured value block 120: charge pressure positioner

Display 1

Display 2

Display 3

Display 4

Charge pressure
positioner, offset
Closed position

Charge pressure
positioner,
Offset
Open position,

Charge pressure
positioner,

-10+10%

-10+10%

XXXX XXXX

Charge pressure
positioner,
Basic voltage position
sensor
3.3 3.9 V

monitoring status

Display value "Charge pressure positioner, monitoring status"

XXXX XXX1 Control element opened fully
XXXX XX1X Control element closed fully
XXXX X1XX Learn release for offset
XXXX 1XXX Offset learning active
XXX1 XXXX Opened stop learnt successfully
XX1X XXXX Closed stop learnt successfully
X1XX XXXX Offset learning completed
1XXX XXXX Cleaning/verify function active

14

Title orAudi
name,
division,
ATU,
8/2010Date

0.65 0.85 V

Replacing turbocharger vacuum units 2.0l CR TDI transversally

installed
Causes of P0234, P0299 and P2563

15

- Vacuum hose twisted,

kinked

- Charge pressure hose loose

ripped

Title orAudi
name,
division,
ATU,
8/2010Date

leaky/not connected

vacuum unit leaky

Thank you.

16

Title or name, division, Date