Replacing vacuum unit with position sender for charge pressure positioner G581 — AUDI

🧭 Before you start

Fits: platform code 2C0

• Renewed: nuts

Don't miss

• When detaching the oil supply line, counterhold the connection. Risk of damage as a consequence! — Prepare a 14 mm open-ended wrench for counterholding.
• Counterhold connection piece and unscrew oil supply line (arrow) from turbocharger.
• Counterhold lock nut (B) with ring spanner T10423 and unscrew securing nut (A) from the control rod using socket inset T10422.
• Make sure that the guiding element moves easily along the control rod.Because of its high degree of alloying, the securing nut is not magnetic. A magnet can be used for support.
• Counterhold locknut(B) and screw securing nut(A) onto the control rod towards the adjusting lever. Tighten slightly with a ring spanner T10423.

🔧 Engine codes this applies to

📐 61 workshop diagrams for CFHC

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. ⚠ The special tools indicated, in particular 10 mm hexagon socket T10422 or 10 mm hexagon socket T10422 A. are designed solely to be used in accordance with the following procedures and must not be used for other threaded connections. There is a danger of deformation if high torques are applied. — Remove air filter housing with air mass meter and connecting pipe .
2. Open heat shield gaiter (1) from charge pressure servo position sender G581(3).
3. Disconnect and pull off electrical connector (2) on charge pressure servo position sender G581(3).
4. Remove crankcase breather hose (1), press release buttons for this.
5. Unclip vacuum lines (arrows) and place to one side.

6. Unscrew bolt (2) (captive bolt). Twist intake hose (3) clockwise out of its holder and remove.
7. Seal opening in turbocharger with sealing cap from replacement parts kit.
8. Open bracket (2) and unhook vacuum hose (1).
9. Pull off vacuum hose (1) from vacuum unit on turbocharger.
10. Unscrew securing nut (arrow) where the oil supply line/vacuum line is connected to the cylinder head.
11. ⚠ When detaching the oil supply line, counterhold the connection. Risk of damage as a consequence! — Prepare a 14 mm open-ended wrench for counterholding.
12. Counterhold connection piece and unscrew oil supply line (arrow) from turbocharger.
13. Seal oil supply opening in turbocharger with plug from replacement parts kit.
14. Counterhold lock nut (B) with ring spanner T10423 and unscrew securing nut (A) from the control rod using socket inset T10422.
15. Unscrew securing bolts of the vacuum unit (arrows) and remove the vacuum unit (A).
16. ⚠ Only use new nuts and bolts from replacement parts kit! — If necessary, remove lower securing nut of the control rod from the new vacuum unit.
17. Screw locknut by hand onto the control rod as far as possible in the direction of the vacuum unit.
18. Push control rod through adjusting lever, fit vacuum unit (A) and tighten fastening bolts by hand.
19. Tighten securing bolts (arrows). [Note: Make sure that the guiding element moves easily along the control rod.Because of its high degree of alloying, the securing nut is not magnetic. A magnet can be used for support.]
20. Connect hand vacuum pumpVAS 6213 to vacuum unit.
21. Fit securing nut by hand (A).
22. Allow partial vacuum to escape from the vacuum unit.
23. Remove protective cap, fit oil supply line to turbocharger and tighten.
24. Fit connector (2) to position sender for charge pressure servo G581(3)and close heat protection mat (1).
25. Connect .
26. Select Engine electronics on display.
27. Click the 011 - Measured values button on the display.
28. In the selection list, select "“Positioner for high pressure, turbocharger, actual input voltage”" and switch until measured value is displayed.
29. Connect hand vacuum pumpVAS 6213 to vacuum unit.
30. Observing the displayed measured value, set a voltage of 760 mV by causing a vacuum of max. 0.65 bar.
31. ⚠ During the following procedure for adjusting the control rod, keep the partial vacuum and thus the voltage of 0.760 V constant. — Slowly screw the locknut(B) of the control rod downwards by hand. Adjusting lever rests against lower »stop«.
32. Counterhold locknut(B) and screw securing nut(A) onto the control rod towards the adjusting lever. Tighten slightly with a ring spanner T10423.
33. Allow partial vacuum to escape from the vacuum unit.
34. Observe the lowest value of the measured value block. When there is no pressure, the value should be 3.00 to 3.40 V.
35. Fit socket inset T10422, counterhold locknut (B) with ring spanner T10423 and tighten securing nut (A).
36. ⚠ Cause a partial vacuum of 0.65 ± 0.05 bar to act on the vacuum unit in order to ensure that the adjusting lever rests against the »stop«. When this is done, the voltage should automatically be set to 0.760 V. — Press locking plate by hand onto the control rod and, if possible, turn 90° in the (direction of the arrow).
37. Seal connection between control rod/securing nut with sealing paint from replacement parts kit.
38. Counterhold locknut (B), undo securing nut (A) of the control rod and correct the voltage by turning the locknut (B).
39. Counterhold locknut (B), turn securing nut (A) in opposing direction and tighten it with socket inset T10422.
40. Press locking plate by hand onto the control rod and, if possible, turn 90° in the (direction of the arrow).
41. Seal connection between control rod/securing nut with sealing paint from replacement parts kit.
42. Fit vacuum hose (1) to vacuum unit on turbocharger.
43. Engage vacuum hose (1) and close bracket (2).
44. Fit securing nut (arrow) connecting the oil supply line/vacuum line to the cylinder head and tighten it.
45. Remove sealing cap from turbocharger.
46. When mounting intake connecting pipe on turbocharger, it must be ensured that intake connecting pipe is correctly seated on the bolt of the turbocharger. (arrow).
47. Complete the engine.
48. Start engine and clear event memory .
49. Check setting as follows:
50. Click the button 006 - Basic setting on the display.
51. Select Adaptation of turbocharger from selection list.
52. Click the button Measured values on the bottom right on the display.
53. Select Positioner for high pressure, turbocharger, actual input voltage from selection list.
54. Click the Start button on the bottom right on the display.
55. Observe value in lower part of screen. Value must fluctuate between 0.65 ... 0.85 and 3.00 ... 3.40 V (vacuum unit is moved to both end stops alternately).
56. End basic setting procedure.

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