Removing and installing vacuum unit with position sender 2 for charge pressure positioner G580 — VW

Removing and installing vacuum unit with
position sender 2 for charge pressure positioner
G580
Special tools and workshop equipment required
Hand vacuum pump
VAS 6213
Turbocharger tester
V.A.G 1397A
Torque wrench
V.A.G 1783
Vehicle diagnostic tester
Removing
Remove rear engine mounting
Chapter
.
Remove rear engine support
Chapter
.
Pull off vacuum hose
1
.
Disconnect electrical connector
2
.
Release securing clip
1
.
Remove nut
2
.
Unscrew vacuum line holder from vacuum unit.
Unscrew bolts
3
.
Remove vacuum unit with
position sender 2 for charge pressure positioner
G580
4
.
Installing
Installation is carried out in the reverse order; note the following:
If vacuum unit was renewed with
position sender 2 for charge pressure positioner
G580
, original dimension
a
of control rod must be determined.
Transfer calculated dimension
a
to new threaded rod. To do this, unscrew nut until dimension
a
is correct.
Guided threaded rod
1
of vacuum unit through opening of lever arm
3
.
Tighten bolts
4
.
Screw on nut
2
by hand.
Connect electrical connector
5
.
Connect
Vehicle diagnostic tester
.
Switch ignition on.
Read voltage value
Vehicle diagnostic tester
,
01 - Systems capable of self-diagnosis
,
01 - Diesel direction injection and preglow system EDC 17
,
01 - Engine electronics functions
,
01 Reading measured values
.
Connect
turbocharger tester
V.A.G 1397A
and
hand vacuum pump
VAS 6213
to vacuum connection of vacuum unit
1
of
position sender 2 for charge pressure positioner
G580
using a commercially available T-piece
2
.
Switch
turbocharger tester
V.A.G 1397A
on and move sliding switch on device to position II.
Generate a vacuum of 500 ± 50 mbar in
position sender 2 for charge pressure positioner
G580
.
Move lever arm
1
in direction of
arrow
to closed position.
Turn nut
2
until it comes into contact with lever arm
1
.
Continue to turn nut
2
until
Vehicle diagnostic tester
displays a voltage value of 0.75 V ± 0.05 V for
position sender 2 for charge pressure positioner
G580
.
Then tighten lock nut
3
. Counterhold nut
2
to do this.
Slowly reduce vacuum. Lever arm
1
now moves in direction of
arrow
to open position.
Generate a vacuum of 500 ± 50 mbar again in
position sender 2 for charge pressure positioner
G580
.
Check setting position once again via voltage value 0.75 V ± 0.02 V of
position sender 2 for charge pressure positioner
G580
; adjust again if necessary.
Control flap is now in closed position. Press against lever arm
1
to determine whether control flap is completely closed.
Lever arm
1
or control flap must now rest against inner stop.
If lever arm is not resting against stop, setting must be carried out again until set values agree with each other.
Slowly reduce vacuum.
Then secure nut and locknut with sealing paint from repair set
Electronic Parts Catalogue
.
Push securing clip back onto control rod and turn 90°.
Specified torques
Chapter
“
Assembly overview - turbocharger, bi-turbo
”
Chapter
“
Assembly overview - assembly mountings
”