Removing and installing regulating flap potentiometer G584 — VW

Removing and installing regulating flap potentiometer
G584
Special tools and workshop equipment required
Hand vacuum pump
VAS 6213 or hand vacuum pump
V.A.G. 1390.
Turbocharger tester
V.A.G 1397A
Torque wrench
V.A.G 1783 with open end spanner insert AF10
V.A.G 1783/1
Vehicle diagnostic tester
Note
A replacement-parts kit is available for replacing the regulating flap potentiometer
G584.
Electronic Parts Catalogue
Removing
Detach vacuum hose (2) from upper toothed belt guard (1).
Remove pipe (arrow) from cylinder head cover.
Detach hoses from connecting hose (3) bracket (arrow).
Release and pull off wiring harness connector (2)
. Detach wiring harness (2) from connecting hose retainer (3).
Open clips (1) and (4).
Remove connecting hose (3).
Pull hose off regulating flap potentiometer
G584 (2).
Unclip connector (1) from regulating flap potentiometer
G584 (2).
Only for vehicles with charge air pressure sender 2
G447 on turbocharger.
Detach connector (2) from charge air pressure sender 2
G447 (1).
Undo and remove bolts (2) securing bracket for charge air pressure sender 2
G447 (1) and place charge air pressure sender 2
G447 to one side.
Continuation for all vehicles
Seal opening (3) of turbocharger with a suitable cover.
Undo and remove bolts (2) securing heat shield (1) and remove heat shield.
Undo and completely remove nut (2) securing control rod.
Counterhold lock nut (3) with open-end spanner.
Working from below, undo and remove nuts securing regulating flap potentiometer
G584 (1) together with bracket (2) to mounting of turbocharger (2 nuts).
Remove
regulating flap potentiometer
G584 upwards together with bracket.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Use only new bolts and nuts from the spare-parts kit if the regulating flap potentiometer
G584 is being replaced completely!
New part
If necessary, remove lower nut securing the control rod of the new regulating flap potentiometer
G584.
Note
Lock nut must have been screwed onto control rod.
Old part
Remove lock nut from control rod and carefully remove the sealing paint from the control rod completely.
Screw new lock nut from spare-parts kit onto control rod again.
Continuation for all
Carefully clean touching surfaces of regulating flap potentiometer
G584 (3) and bracket (2).
Carefully clean mounting for regulating flap potentiometer
G584 on turbocharger.
Insert regulating flap potentiometer
G584 (3) in such a way that the location marker (1) fits into the hole in the bracket (2).
Install
regulating flap potentiometer
G584 and guide control rod (1) through adjusting lever on turbocharger as shown in the illustration.
Fit regulating flap potentiometer
G584 on the turbocharger mounting with new nuts from the spare-parts kit (4) and tighten nuts to 8 Nm.
Screw nuts (2) onto control rod by hand in direction of vacuum unit.
Note
Make sure that the guiding element (1) of the flap lever moves easily along the control rod.
Attach connector (1) to regulating flap potentiometer
G584 (2).
Connect
Vehicle diagnostic tester.
Selecting operating mode:
Press button on display for
“Vehicle self-diagnosis”.
Selecting vehicle system:
Press button
“01 - Engine electronics” on display.
The display indicates the control unit identification and the coding of the engine control unit.
Selecting diagnostic function:
Press button for
“011 - Measured values” on the display.
The display shows the individual components.
Select
“Bypass Valve, Turbocharger, High Pressure Turbine Input, Input Voltage” and confirm entry with (Q).
Connect turbocharger tester
V.A.G 1397A and hand vacuum pump
VAS 6213 or hand vacuum pump
V.A.G. 1390 to vacuum connection (1) of regulating flap potentiometer
G584 using a T-piece to do so.
Switch on turbocharger tester
V.A.G 1397A and move sliding switch on device to position II.
Apply a vacuum of 500 ± 50 mbar to regulating flap potentiometer
G584.
Move flap lever (1) in direction of (arrow) to
“Closed” position, and hold it there.
Screw securing nut (3) in direction of vacuum unit until it contacts flap lever (1).
Continue turning securing nut (3) until a voltage of 0.75 volt ± 0.02 volt of regulating flap potentiometer
G584 is reached.
Tighten lock nut (2) to 8 Nm.
Note
Counterhold on the nut to make sure that the control rod does not turn.
Slowly reduce vacuum. Flap lever (1) now moves in direction of arrow
“Open”.
Apply a vacuum of 500 ± 50 mbar to regulating flap potentiometer
G584 again.
Check voltage setting (0.75 volt ± 0.02 volt) of regulating flap potentiometer
G584 and, if necessary, reset.
Slowly reduce vacuum.
Note
Flap lever (1) must now be resting against the stop. If the flap lever is not resting against the stop, the setting procedure must be repeated until the setting values agree with each other.
After this, secure the nuts and lock nuts with sealing paint from the replacement-parts kit.
Press securing clip from replacement-parts kit onto control rod and turn 90° in direction of arrow.
Tighten securing bolts (2) for heat shield (1).