ATU Audi Technical UpdatesA3 2.0 TDI Turbo Charger Vacuum Unit

2 Title or name, division, Date

Contents: Technical actionsEngine

No. Event Topic Type/model

1 03/10 Replacing turbocharger a vacuum unit A3 and TT

Audi ATU, 8/2010

3 Title or name, division, Date

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

Audi ATU, 8/2010

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► 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

Replacing turbocharger vacuum units 2.0l CR TDI transversally installed

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.

Audi ATU, 8/2010

5 Title or name, division, Date

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 anddetach 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 chargepressure positioner "G581".

- Disconnect vacuum hose "2" from the vacuum unit on theturbocharger.

Audi ATU, 8/2010

6 Title or name, division, Date

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.

Audi ATU, 8/2010

7 Title or name, division, Date

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".

Audi ATU, 8/2010

8 Title or name, division, Date

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 bolts—arrows— to 8 Nm

Note:Ensure that the guide moves smoothly on the control rod.

Audi ATU, 8/2010

9 Title or name, division, Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally installed► Installation:

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

- Plug in connector "2" on the position sender for charge pressurepositioner -G581- and close heat shield mat

Audi ATU, 8/2010

10 Title or name, division, Date

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.

Audi ATU, 8/2010

11 Title or name, division, Date

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 3.30–3.90 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.

Audi ATU, 8/2010

12 Title or name, division, Date

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 waxpaint from the replacement part kit.

Voltage value not OK- Counterhold lock nut "B" and loosen securing nut "A" on the control rod; twist locknut "B" to correct the value.

- Counterhold lock nut "B" and turn securing nut "A" in the oppositedirection 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.

Audi ATU, 8/2010

13 Title or name, division, Date

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 0.65–0.85 V and 3.30–3.90 V (vacuum unit will move alternately to both end stops).

Voltage values OK – exit basic setting!Audi ATU, 8/2010

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Replacing turbocharger vacuum units 2.0l CR TDI transversally installedMeasured value block 120: charge pressure positioner

Display value "Charge pressure positioner, monitoring status"XXXX XXX1 Control element opened fullyXXXX XX1X Control element closed fullyXXXX X1XX Learn release for offsetXXXX 1XXX Offset learning activeXXX1 XXXX Opened stop learnt successfullyXX1X XXXX Closed stop learnt successfullyX1XX XXXX Offset learning completed1XXX XXXX Cleaning/verify function active

Display 1 Display 2 Display 3 Display 4

Charge pressure positioner, offsetClosed position

Charge pressure positioner,

Offset Open position,

Charge pressure positioner,

monitoring status

Charge pressure positioner,

Basic voltage position sensor

-10…+10% -10…+10% XXXX XXXX3.3 … 3.9 V

0.65 … 0.85 V

Audi ATU, 8/2010

15 Title or name, division, Date

Replacing turbocharger vacuum units 2.0l CR TDI transversally installedCauses of P0234, P0299 and P2563

- Vacuum hose twisted, kinked leaky/not connected

- Charge pressure hose loose ripped vacuum unit leaky

Audi ATU, 8/2010

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Thank you.