Audi 0B5, DL501 Oversized Pressure Regulator Valve Kit Tool Kit
T R A N S M IS S ION PART S Instructions
VW/Audi 0B5, DL501
Oversized Pressure Regulator Valve Kit
Pressure Blow-off Bore
Part No.
R
225740-02K
• Valve • O-Rings (2)
EQ
D
TOO L
UIRE
Pressure Regulator Bore
VW/Audi 0B5 Valve Body
1 Extra
OE Valve OE Spring
Tool Kit Valve
Part No.
Tool KIt
F-225740-TL2
OE Spring
• Reamer • Reamer Jig • Guide Pin NOTE: Sonnax “F-Tool” kits designed to service a specific bore require the VB-FIX, a self-aligning valve body reaming fixture. More information and instructions can be found online at www.sonnax.com.
OE Retaining Clip
O-Ring
OE End Plug
1. Disassembly
NOTE: Retaining clip for pressure regulator valve train also secures the pressure blow-off valve train. Pressure blow-off valve train must be removed to facilitate reaming of the pressure regulator bore and reinstalled after reaming.
a. Remove OE retaining clip, end plug and pressure regulator spring. Set aside for reuse. b. Remove and discard OE pressure regulator valve. c. Remove OE pressure blow-off spring and valve, set aside for reuse. 2. Bore Reaming Ream pressure regulator bore (for reaming instructions/reamer care, please visit www.sonnax.com). Sonnax reaming tool kit F-225740-TL2 and VB-FIX are required for this operation. 3. Installation & Assembly a. Ensure all debris has been removed from valve bore and body. b. Reinstall OE pressure blow-off valve and spring. c. Install Sonnax pressure regulator valve. d. Reinstall OE pressure regulator spring, ensuring it seats in the valve spring pocket. e. Remove O-ring from OE end plug and install Sonnax O-ring. Lubricate and roll on clean bench to size O-ring into groove. f. Reinstall OE end plug and secure both valve trains with OE retaining clip. 4. Final Testing Vacuum testing at the port(s) indicated holds the recommended minimum 16 and 18 in-Hg. ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
18"-Hg 20
15
10
25
5
0 30 VACUUM TEST
16"-Hg
VW/Audi 0B5 Valve Body
225740-02K-IN 10-13-15
VW/Audi 0B5, DL501
Oversized Pressure Regulator Valve Kit
Pressure Blow-off Bore
Part No.
R
225740-02K
• Valve • O-Rings (2)
EQ
D
TOO L
UIRE
Pressure Regulator Bore
VW/Audi 0B5 Valve Body
1 Extra
OE Valve OE Spring
Tool Kit Valve
Part No.
Tool KIt
F-225740-TL2
OE Spring
• Reamer • Reamer Jig • Guide Pin NOTE: Sonnax “F-Tool” kits designed to service a specific bore require the VB-FIX, a self-aligning valve body reaming fixture. More information and instructions can be found online at www.sonnax.com.
OE Retaining Clip
O-Ring
OE End Plug
1. Disassembly
NOTE: Retaining clip for pressure regulator valve train also secures the pressure blow-off valve train. Pressure blow-off valve train must be removed to facilitate reaming of the pressure regulator bore and reinstalled after reaming.
a. Remove OE retaining clip, end plug and pressure regulator spring. Set aside for reuse. b. Remove and discard OE pressure regulator valve. c. Remove OE pressure blow-off spring and valve, set aside for reuse. 2. Bore Reaming Ream pressure regulator bore (for reaming instructions/reamer care, please visit www.sonnax.com). Sonnax reaming tool kit F-225740-TL2 and VB-FIX are required for this operation. 3. Installation & Assembly a. Ensure all debris has been removed from valve bore and body. b. Reinstall OE pressure blow-off valve and spring. c. Install Sonnax pressure regulator valve. d. Reinstall OE pressure regulator spring, ensuring it seats in the valve spring pocket. e. Remove O-ring from OE end plug and install Sonnax O-ring. Lubricate and roll on clean bench to size O-ring into groove. f. Reinstall OE end plug and secure both valve trains with OE retaining clip. 4. Final Testing Vacuum testing at the port(s) indicated holds the recommended minimum 16 and 18 in-Hg. ©2015 Sonnax Industries, Inc. 800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com
18"-Hg 20
15
10
25
5
0 30 VACUUM TEST
16"-Hg
VW/Audi 0B5 Valve Body
225740-02K-IN 10-13-15
