Charge Pressure Actuator Position Sensor -G581- WITH THE VACUUM DIAPHRAGM

WARNING: This page is about a different car, the 2014 Volkswagen Jetta, 2013 Volkswagen Jetta, 2012 Volkswagen Jetta, and 2011 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Union Nut Socket T40055
Actuator Socket - 10mm T10422A
Ring Wrench 10x12mm T10423
Wrench - Open End - 14mm T10461
Vehicle Diagnosis Tester

CAUTION:

The specified special tools, in particular the Actuator Socket - 10mm T10422A, are designed exclusively for use according to the following procedure and may not be used for other threaded connections. Higher torques can cause deformation.

NOTE:

There is a replacement kit available for replacing the vacuum diaphragm with the charge pressure actuator position sensor.

Removing

-- Remove the air filter housing with the Mass Airflow Sensor -G70- and connecting pipe. Refer to AIR FILTER HOUSING OVERVIEW .

-- Open the heat shield mat and disconnect the electrical connector -arrow- from the Charge Pressure Actuator Position Sensor -G581-.

Fig 1: Charge Pressure Actuator Position Sensor -G581 Connector

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Jetta from MY 2005 through 2010, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 2009 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 2010

Fig 2: Identifying Release Buttons

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-- Press the release buttons and remove the crankcase ventilation connecting pipe -1- from the cylinder head cover.

-- Unclip the vacuum hoses -arrows-.

-- Remove the bolt -2- (keep the bolt for installation) and tilt the charge air pipe with the intake tube backward and remove it from the turbocharger.

-- Seal the opening in the turbocharger with the cap from the replacement part kit.

Jetta from MY 2011

Fig 3: Expose The Vacuum Hoses

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-- Unclip the vacuum hoses -arrows-.

-- Press the release buttons and remove the crankcase ventilation connecting pipe -3- from the cylinder head cover.

Fig 4: Identifying Release Buttons & Crankcase Ventilation Connecting Pipe

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-- Disconnect the connector -2-.

-- Remove the bolt -1- (keep the bolt for installation) and tilt the charge air pipe with the intake tube backward and remove it from the turbocharger.

-- Seal the opening in the turbocharger with the cap from the replacement part kit.

-- Remove the bolt -1- and remove the warm air pipe from the guide -2-.

Fig 5: Identifying Warm Air Pipe & Bolt

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Continuation for All

-- Remove the vacuum line from the turbocharger.

-- Remove the nut -arrow- for the oil supply line/vacuum line connection from the cylinder head.

Fig 6: Identifying Cylinder Head Clamp Nut

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CAUTION:

When disconnecting the oil supply line, the connection fitting must be counter held to avoid the risk of consequential damage.

-- Counter hold the connection using the Wrench - Open End - 14mm T10461 and remove the oil supply line -arrow- from the turbocharger using the Union Nut Socket T40055.

Fig 7: Identifying Connection To Oil Supply Line

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-- Seal the oil supply line opening in the turbocharger with the plug from the replacement part kit.

Jetta from MY 2011

Fig 8: Identifying Socket 10 Mm T10422

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-- Set the Actuator Socket - 10mm T10422A to dimension -A-.

A = 57 mm

Continuation for All

Fig 9: Identifying Ring Spanner & Socket 10 Mm T10422 -2- With A Ratchet -3- Installed

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-- Install the Ring Wrench 10x12mm T10423 -1- and the Actuator Socket - 10mm T10422A -2- with a ratchet -3- as shown in the figure.

-- Counter hold the lock nut -B- with the Ring Wrench 10x12mm T10423 and unscrew the securing nut -A- with the Actuator Socket - 10mm T10422A from the control rod.

Fig 10: Identifying Lock Nut & Securing Nut

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-- Remove the bolts -arrows- and remove the vacuum actuator -A-.

Fig 11: Identifying Vacuum Actuator & Bolts

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Installing

CAUTION:

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

-- Remove the securing nut for the control rod from the new vacuum actuator, if applicable.

-- Screw the lock nut onto the control rod by hand to the stop, in the direction of the vacuum actuator.

-- Connect the control rod through the adjustment lever on the turbocharger, install the vacuum actuator -A-, and install the bolts -arrows-.

Fig 12: Identifying Vacuum Actuator & Bolts

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-- Tighten the vacuum actuator bolts -arrows- to 8 Nm.

NOTE:

Ensure that the guide piece moves easily on the control rod.

-- Remove the protective cap, install the oil supply line to the turbocharger, and tighten the fitting to 22 Nm.

-- Connect the connector -2- to the Charge Pressure Actuator Position Sensor -G581- and connect the heat shield mat.

Fig 13: Connect The Connector -2-

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-- Connect the vehicle diagnostic tester.

Selecting the Operating Mode

-- Press the "vehicle self-diagnosis" button on the display.

Selecting the Vehicle System

-- Press the "01 - engine electronics" button on the display.

The display shows the control module identification and the coding for the Engine Control Module -J623-.

Selecting the Diagnosis Function

-- Press the "011 - measured values" button on the display.

-- Enter measured value block "120" via the 10 key keyboard and confirm the entry with the "Q" button.

-- Connect the Hand Vacuum Pump VAS 6213 to the vacuum actuator.

-- Set a voltage of 0.760 volts by generating a vacuum while observing the lowest value of the measured value block.

CAUTION:

Maintain a constant vacuum and voltage of 0.760 volts during the subsequent adjustment procedure for the control rod.

-- Slowly screw the lock nut -B- on the control rod down by hand. The adjustment lever is on the lower "stop".

Fig 14: Identifying Lock Nut & Securing Nut

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Counter hold the lock nut -B- and turn the securing nut -A- on the control rod against the adjustment lever. Tighten lightly using the Ring Wrench 10x12mm T10423.

-- Release the vacuum pressure from the vacuum actuator.

-- Observe the lowest value of the measured value block. With no pressure, a value of 3.30-3.90 volts must be set.

-- Install the Actuator Socket - 10mm T10422A, counter hold the lock nut -B- using the Ring Wrench 10x12mm T10423 and tighten the securing nut -A-.

CAUTION:

Generate a vacuum of 0.75 ± 0.05 bar at the vacuum actuator to ensure that the adjustment lever is at the "stop". A voltage of 0.760 volts must be set in this process.

Voltage Value is OK

-- Manually press the securing plate onto the control rod and turn it 90° (1/4) turn in the -direction of arrow-.

Fig 15: Identifying Securing Plate

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-- Seal the control rod/securing nut connection with sealing wax from the replacement part kit.

Voltage Value is not OK

-- Counter hold the lock nut -B-, loosen the securing nut -A- for the control rod, and correct the value by rotating the lock nut -B-.

Fig 16: Identifying Lock Nut & Securing Nut

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-- Counter hold the lock nut -B-, turn the securing nut -A-, and tighten using the Actuator Socket - 10mm T10422A.

-- Manually press the securing plate onto the control rod and turn it 90° (1/4) turn in the -direction of arrow-.

Fig 17: Identifying Securing Plate

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-- Seal the control rod/securing nut connection with sealing wax from the replacement part kit.

Continuation

-- Install the nut -arrow- for the oil supply line/vacuum line connection to the cylinder head and tighten.

Fig 18: Identifying Cylinder Head Clamp Nut

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-- Install the cover on the turbocharger.

-- Reassemble the engine.

-- Start the engine and erase the Diagnostic Trouble Code (DTC) memory.

-- Check the setting as follows:

Selecting the Diagnosis Function

-- Press the "006 - basic setting" button on the display.

-- Enter measured value block "120" via the 10 key keyboard and confirm the entry with the "Q" button.

-- Press the "activate" button on the lower half of the screen.

-- Observe the value in the lower window. It must fluctuate between 0.65-0.85 volts and 3.30-3.90 volts (vacuum actuator alternates between the two end positions).

If the voltage values are OK:

-- End the basic setting.