Turbocharger

Turbocharger Vacuum Diaphragm

• Socket 10 mm (T10422 A) replaces the current socket 10 mm (T10422). For engine code CJAA, socket 10 mm (T10422 A) is required to be used.

Special tools, testers and auxiliary items required

• Socket 10 mm (T10422 A)

• Ring Spanner 10 x 12 (T10423)

• Hand Vacuum Pump (VAS 6213)

• Open End Wrench 14 mm (T10461)

• Vehicle Diagnostic Tester


The special tool that is mentioned here - the socket 10 mm (T10422 A) , has been designed to be used solely in accordance with the following procedure, and must not be used on any other threaded connections. Higher torques can cause deformation.

• A replacement part kit is available for the replacement of the vacuum diaphragm with the charge pressure actuator position sensor. Refer to the Parts Catalog.

Removing

- Remove the air filter housing with the Mass Airflow (MAF) sensor and intake hose. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.

- Open the heat shield mat and disconnect the electrical harness connector - arrow - from the charge pressure actuator position sensor.






- Squeeze the release buttons and remove the crankcase vent tube - 1 - from the cylinder head cover.

- Remove the vacuum hoses - arrows - from the clip.






- Loosen the bolt - 2 - (cannot be lost) and tilt the air guide pipe with the intake tube backward and remove from the turbocharger.






- Seal the opening on the turbocharger with the cap from the replacement part kit.

- Remove the bolt - arrow -, and remove the warm air connection - 1 - if necessary.






- Remove the vacuum line from the turbocharger.

- Remove the nut - arrow - for the oil supply line/vacuum line connection from the cylinder head.







When disconnecting the oil supply line, the connection fitting must be counter held. Risk of consequential damage.

- Counter hold the connection using the open end wrench 14 mm (T10461) and remove the oil supply line - arrow - from the turbocharger.






- Seal the oil supply line opening on the turbocharger with a plug from the replacement part kit.

- Counter hold the locking nut - B - using the ring spanner 10 x 12 (T10423) and remove the nut - A - using the socket 10 mm (T10422 A) from the control rod.






- Remove the vacuum diaphragm bolts - arrows - and remove the vacuum diaphragm- A -.






Installing


Only use new bolts and nuts from the replacement part kit.

- Remove the lower nut for the control rod from the new vacuum diaphragm if applicable.

- Screw the lock nut onto the control rod by hand to the stop in the direction of the vacuum diaphragm.

- Insert the control rod through the adjustment lever on the turbocharger, install the vacuum diaphragm - A -, and the bolts - arrows -.

- Tighten the bolts - arrows - to 8 Nm.






• Ensure that the guide piece moves easily on the control rod.

- Connect the hand vacuum pump (VAS 6213) to the vacuum diaphragm and create a vacuum.

• The nut is not magnetic due to its high alloy composition. Do not use a magnet as a support.

- Install the nut - A -.






- Release the vacuum pressure from the vacuum diaphragm.

- Remove the protective cap, install the oil supply line to the turbocharger, and tighten it to 22 Nm.

- Connect the connector - 2 - to the charge pressure actuator position sensor and connect the heat shield mat.






- Connect the vehicle diagnostic tester.

Select the Operating Mode

- Press the "vehicle self-diagnosis" button on the display.

Select the Vehicle System

- Press the "01 - engine electronics" button on the display.

The display shows the control module identification and the coding for the engine control module.

Select the diagnostic Function

- Press the "011 - measured values" button on the display.

- Enter measured value block "120" via the 10 key keyboard and confirm the entry with the "Q" button.

- Connect the hand vacuum pump (VAS 6213) to the vacuum diaphragm.

- Set a voltage of 0.760 volts by generating a vacuum while observing the lowest value of the measured value block.


Maintain a constant vacuum and voltage of 0.706 V during the subsequent adjustment procedure for the control rod.

- Slowly screw the lock nut - B - on the control rod down by hand. The adjustment lever is on the lower "stop".






- Counter hold the lock nut - B - and turn the securing nut - A - on the control rod against the adjustment lever. Tighten slightly using the ring spanner 10 x 12 (T10423).

- Release the vacuum pressure from the vacuum diaphragm.

- Observe the lowest value of the measured value block. With no pressure, a value of 3.30 to 3.90 volts must be set.

- Position the socket 10 mm socket wrench (T10422 A) , counter hold the locking nut - B - using the ring spanner 10 x 12 (T10423) and tighten the nut - A -.


Generate a vacuum of 0.75 +/- 0.05 bar at the vacuum diaphragm to ensure that the adjustment lever is at the "stop". A voltage of 0.760 volts must be set in this process.

Voltage value is OK

- Manually press the securing plate onto the control rod and turn it 90° (1/4) turn in the - direction of the arrow -.






- Seal the control rod/securing nut connection with sealing wax from the replacement part kit.

Voltage value is not OK

- Counter hold the lock nut - B -, loosen the securing nut - A - on the control rod, and correct the value by rotating the lock nut - B -.






- Counter hold the locking nut - B -, turn the nut - A - in a counter rotation, direction using the socket 10 mm (T10422 A).

- Manually press the securing plate onto the control rod and turn it 90° (1/4) turn in the - direction of the arrow -.






- Seal the control rod/securing nut connection with sealing wax from the replacement part kit.

Continuation

- Install the nut - arrow - for the oil supply line/vacuum line connection on the cylinder head and tighten.






- Remove the plug on the turbocharger.

- Reassemble the engine.

- Start the engine and erase the Diagnostic Trouble Code (DTC) memory. Refer to the vehicle diagnostic tester.

- Check the setting as follows:

Select the Diagnostic Function

- Press the "006 - basic setting" button on the display.

- Enter measured value block "120" via the 10-key keyboard and confirm the entry with the "Q" button.

- Press the "activate" button on the lower half of the screen.

- Observe the value in the lower window. It must fluctuate between 0.65 to 0.85 volts and 3.30 to 3.90 volts (vacuum diaphragm alternates between the two end positions).

If the voltage values are OK:

- End the basic setting.