Removing and installing intake manifold flap motor V157 or intake manifold flap 2 motor V275 — VW

Removing and installing intake manifold flap motor
V157 or intake manifold flap 2 motor
V275
Special tools and workshop equipment required
Electronics box
VAS 6395/1
Connector cable
VAS 6395/4-2
Removing
Note
The procedure for removal and installation of the intake manifold flap motor
V157 for cylinder bank 1 (right) is described as an example. The same approach should be applied as appropriate for intake manifold flap 2 motor
V275.
Proceed as follows:
Carefully pull engine cover panel off four retaining pins one after the other (arrows)
Disconnect electrical connector (3) at air mass meter
G70.
Remove air hose (4) between air filter and turbocharger.
Open red cover over positive terminal on plenum chamber bulkhead.
Connect electronics box
VAS 6395/1 with connector cable
VAS 6395/4-2 to positive terminal grip
“+” and to earth.
Checking software version of electronics box
VAS 6395/1:
Caution
Risk of damage to intake manifold flap motors.
For further procedure first check for correct software download in the electronics box
VAS 6395/1
, to do this proceed as follows:
Indicated on display of
VAS 6395/1 (2 seconds after connecting voltage supply) with correct software download:
>TEST
LEARN
Note
The following appears on display with incorrect software download:
1. START
2. NEXT
In this case the correct software must be downloaded via
“Volkswagen ServiceNet”,
“Workshop Equipment”.
Continuation of procedure:
Separate electrical connection for intake manifold flap motor
V157.
Connect connector cable
VAS 6395/4-2 to intake manifold flap motor
V157 and to electronics box
VAS 6395/1.
Indicated on display of
VAS 6395/1:
>TEST
LEARN
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
CHECK
S: XX % I: XX %
The electronics box
VAS 6395/1 checks the adjustment range of intake manifold flap motor
V157 in stages and checks the feedback of the positions.
Indicated on display of
VAS 6395/1 if intake manifold flap motor
V157 is OK:
ACTUATOR O.K.
The check is completed.
Separate electrical connectors for electronics box
VAS 6395/1.
Installation is carried out in the reverse order.
Indicated on display of
VAS 6395/1 if intake manifold flap motor
V157 is not OK:
PROBLEM
Intake manifold flap motor
V157 must be renewed.
To do this, perform the following procedure:
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
>TEST
LEARN
Press
↓ button item 6.
Indicated on display of
VAS 6395/1:
TEST
>LEARN
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
STEP 1
Using buttons
↑ item 5 and
↓ item 6
, adjust intake manifold flap motor
V157 so that the coupling rod is accessible for removing.
Unclip coupling rod (1) off intake manifold flap motor
V157.
Note
Disregard items
2, 3 and 4.
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
STEP 2
If fitted, remove electrical connector (arrow) for exhaust gas temperature sender 1
G235 from bracket.
Separate connector cable
VAS 6395/4-2 item 3 from intake manifold flap motor
V157.
Caution
The voltage supply for electronics box
VAS 6395/1 must remain connected.
Remove bolts (2) and (4).
Remove and dispose of old intake manifold flap motor
V157.
Install new intake manifold flap motor
V157 in reverse order and clip on coupling rod.
Note
Proceed as follows on version with self-locking bolt: Start bolt by hand and screw in so that it can pick up the old threads. Then tighten bolts to prescribed torque.
Connect connector cable
VAS 6395/4-2 to intake manifold flap motor
V157.
To confirm that the new intake manifold flap motor
V157 was installed, press the v button item 4.
Indicated on display of
VAS 6395/1:
STEP 3
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
WARNING
LEARNING
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
TEST 1
S: 84.0 % I: XX %
Specification: I = 84 %.
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
TEST 2
S: 16.0 % I: XX %
Specification: I = 16 %.
To continue, press v button item 4.
Indicated on display of
VAS 6395/1:
TEST 3
S: XX % I: XX %
The adjustment range of intake manifold flap motor
V157 is run through.
Indicated on display of
VAS 6395/1:
OK
To confirm, press v button item 4.
The setting is complete.
Separate electrical connectors for electronics box
VAS 6395/1.
Installation is carried out in the reverse order.