Removing and installing pressure differential sender G505 or pressure differential sender 2 G524 — VW

Removing and installing
pressure differential sender
G505
or
pressure differential sender 2
G524
The
pressure differential sender
G505
is connected to a measuring point in front of particulate filter on right (bank 1) by means of a pipe.
The second measuring cable is approx. 7 cm long and is exposed to atmospheric pressure (relative pressure sensor concept).
The
pressure differential sender
G505
determines the charge status of particulate filter on right.
Pressure differential sender 2
G524
is connected to a measuring point in front of particulate filter on left (bank 2) by means of a pipe.
The second measuring cable is approx. 7 cm long and is exposed to atmospheric pressure (relative pressure sensor concept).
Pressure differential sender 2
G524
determines the charge status of particulate filter on left.
Special tools and workshop equipment required
Engine and gearbox jack
V.A.G 1383 A
Gearbox support
T10337
Removing
Remove engine cover panel
Chapter
.
Open clips of intake hoses
A
and
B
and remove intake hoses.
Remove rear noise insulation
Rep. gr.
50
.
Remove particulate filters on left and right
Chapter
.
Detach propshaft at rear from gearbox
Transfer box and axle drives
Rep. gr.
39
.
Push rear of propshaft and rear axle drive together; the constant velocity joints can be displaced axially.
Pressure differential sender 2
G524
(left):
Remove left catalytic converter
Chapter
.
Pressure differential sender
G505
(right):
Remove propshaft from front of transfer box
Transfer box and axle drives
Rep. gr.
39
.
Remove right catalytic converter
Chapter
.
Continuation for both sides:
Place ram of engine and gearbox jack
V.A.G 1383 A
with mounted
gearbox support
T10337
under gearbox and brace gearbox in place.
WARNING
Risk of accidents.
It is not permissible to remove the
engine and gearbox jack
V.A.G 1383 A
during installation work or to leave it under the vehicle without supervision.
Unscrew bolts
1
for gearbox support.
Lower gearbox with
engine and gearbox jack
V.A.G 1383 A
and the distance
a
.
Dimension
a
= about 90 mm.
Pressure differential sender 2
G524
(left):
Detach electrical connector
2
and remove bolt
1
.
If the hoses
4
of the pressure sensor are to be removed, open hose clips and spray the two hoses with silicon-free lubricant.
Pressure differential sender
G505
(right):
Detach electrical connector
2
and remove bolt
3
.
If the hoses
4
of the pressure sensor are to be removed, open hose clips and spray the two hoses with silicon-free lubricant.
Continuation for both sides:
Pull hoses carefully and straight from unions (unions break off pressure sensor very easily).
Installing
Installation is carried out in the reverse order; note the following:
Assembly overview - tightening torque: Lambda probes, exhaust temperature and pressure senders
Chapter
Note
Blow compressed air through hoses in direction of particulate filter in order to remove clogging or ice resulting from condensation.
Make sure that hoses are securely fitted and seal properly.
If pressure line has become loose at particulate filter, tighten pressure line to 45 Nm.
Secure all hose connections with the hose clips corresponding to original equipment
Parts catalogue
.
Attach all cable ties in the same places when installing.
Install gearbox support
Rep. gr.
37
.
Install catalytic converter
Chapter
.
Install propshaft for front transfer box
Transfer box and axle drives
Rep. gr.
39
.
Mount propshaft on rear axle drive
Transfer box and axle drives
Rep. gr.
39
.
Install particulate filter
Chapter
.
Install rear noise insulation
Rep. gr.
50
.
Adaptation must be performed after replacement of
pressure differential sender
G505
or
differential pressure sender 2
G524
and/or particulate filter. The procedure is also described under
“Guided Functions”
.