Volkswagen Golf Variant / Jetta. Manual - part 425

 

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Volkswagen Golf Variant / Jetta. Manual - part 425

 

 

There is a replacement part kit available for replacing the vacuum

diaphragm with Charge Air Pressure Actuator Position Sensor -

G581- . Refer to Parts Catalog.

Removing
– Remove the air filter housing with the mass air flow sensor and

connecting pipe. Refer to

⇒ “3.14 Overview - Air Filter”, page 335

 .

– Open the heat shield mat and disconnect the connector

-arrow- from the Charge Air Pressure Actuator Position Sen‐

sor - G581- .

- All Vehicles Except Jetta from MY 2011
– Press the release buttons and remove the crankcase ventila‐

tion connecting pipe -1- from the cylinder head cover.

– Free up the vacuum hoses -arrows-.
– Unscrew the bolt -2- (permanent) and tilt the air duct pipe with

the intake tube toward the rear and remove from the turbo‐

charger.

– Seal the opening on the turbocharger with the cap from the

replacement part kit.

Jetta from MY 2011
– Free up the vacuum hoses -arrows-.

3. Turbocharger    

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tion connecting pipe -3- from the cylinder head cover.

– Disconnect -2-.
– Loosen the bolt -2- (permanent) and tilt the air guide pipe with

the intake tube backward and remove from the turbocharger.

– Seal the opening on the turbocharger with the cap from the

replacement part kit.

– Remove the bolt -1- and the warm air pipe from the guide

-2-.

Continuation for All Vehicles
– Remove the vacuum line on the turbocharger.
– Unscrew the securing nut -arrow- of the oil supply line/vacuum

line connection on the cylinder head.

Caution

When disconnecting the oil supply line, the connection must

be counter-held. Risk of subsequent damage.

– Prepare 14 mm open end wrench as shown for counter-hold‐

ing purposes.

14 mm Tool for Counter-Holding the Oil Supply Line Connection

Fitting
♦ A = 110 mm
♦ B = 25 mm

284

14mm - T10461- and remove the oil supply line -arrow- from

the turbocharger using the Union Nut Socket - T40055- .

– Seal the oil supply opening on the turbocharger with plugs

from the replacement part kit.

Jetta from MY 2011
– Set the Actuator Socket - 10mm - T10422A- to the dimension

-A-.

♦ A = 57 mm

Continuation for All Vehicles
– Position the Ring Wrench 10x12mm - T10423- -1- and Actua‐

tor Socket - 10mm - T10422A- -2- with the Reversible Ratchet

-3- as shown.

– Counterhold the lock nut -B- with the Ring Wrench 10x12mm

- T10423- and unscrew the securing nut -A- with the Actuator

Socket - 10mm - T10422AA- from the control rod.

3. Turbocharger    

285

vacuum diaphragm -A-.

Installing

Caution

Only use new screws and nuts from the replacement part kit.

– Remove the lower nut of the control rod from the new vacuum

diaphragm if necessary.

– Screw the lock nut onto the control rod by hand to the stop in

the direction of the pressure cell.

– Conduct the control rod through the adjusting lever on the tur‐

bocharger, install the vacuum diaphragm -A-, and insert the

bolts.

– Tighten the bolts -arrows- to 8 Nm.

Note

Ensure that the guide moves easily on the control rod.

– Remove the protective cap, install the oil supply line on the

turbocharger, and tighten to 22 Nm.

– Connect the connector -2- to the Charge Air Pressure Actuator

Position Sensor - G581- and connect the heat shield mat.

– Connect the Vehicle Diagnostic Tester .
Selecting Operating Mode:
– Press the “vehicle self-diagnosis” button on the display.
Vehicle System Selection:
– Press the “01 - engine electronics” button on the display.
The display shows the control module identification and the cod‐

ing for the engine control module.
Selecting Diagnosis Function:
– Press the “011 - measured values” button on the display.
– Enter the measured value block “120” via the 10-key keyboard

and confirm the input with the “Q” button.

– Connect the Hand Vacuum Pump - VAS6213- to the vacuum

diaphragm.

– Set a voltage of 0.760 V by generating a vacuum while ob‐

serving the lowest value of the measured value block.

Caution

Maintain a constant vacuum and voltage of 0.706 V during the

subsequent adjustment procedure for the control rod.

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