Vacuum Diaphragm with Charge Pressure Actuator Position Sensor G581
Vacuum Diaphragm with Charge Pressure Actuator Position Sensor G581
Special tools, testers and auxiliary items required
• Socket 10 mm (T10422 A)
• Ring Spanner 10 x 12 (T10423)
• Hand Vacuum Pump (VAS 6213)
• Engine Bung Set (VAS 6122)
• Vehicle Diagnostic Tester
The specified special tools, in particular the socket 10 mm (T10422 A) , are designed exclusively for use according to the following procedure and may not be used for other connections. Higher torques can cause deformation.
• A replacement part kit is available for the replacement of the vacuum diaphragm with the charge pressure actuator position sensor. Refer to the Parts Catalog.
Removing
- Remove the engine cover. Refer to => [ Engine Cover ] Engine Cover.
- Open the heat shield mat and disconnect the electrical harness connector - arrow - from the charge pressure actuator position sensor.
- Press the release buttons and remove the crankcase ventilation connecting pipe - 1 - from the cylinder head cover.
- Disconnect the connector and remove it from the crankcase ventilation hose - 1 -.
- Expose the vacuum hoses - arrows -.
- Remove the bolt - 2 - (cannot be lost) and tilt the air guide pipe with the intake tube backward and remove from the turbocharger.
- Remove the bolt - arrow -.
- Unclip the preheating pipe - 1 - and remove it from the bracket.
- Seal the opening on the turbocharger with the cap from the engine bung set (VAS 6122).
- Remove the vacuum line from the vacuum diaphragm.
- Counter hold the locking nut - B - and remove the nut - A - using the socket 10 mm (T10422 A) from the control rod.
- Remove the vacuum diaphragm bolts - arrows - and remove the vacuum diaphragm along with the charge pressure actuator position sensor - A -.
Installing
Only use new bolts and nuts from the replacement part kit.
- Remove the lower nut of the control rod from the new vacuum diaphragm, if applicable.
- Screw the lock nut onto the control rod by hand to the stop in the direction of the vacuum diaphragm.
- Push the control rod through the adjustment lever on the turbocharger, install charge pressure actuator position sensor - A -, and insert the bolts.
- Tighten the bolts - arrows - to 8 Nm.
• Ensure that the guide piece moves easily on the control rod.
- Connect the connector - arrow - to the charge pressure actuator position sensor and connect the heat shield mat.
- 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 for the engine control module.
Selecting the Diagnostic Function
- Press the "011 - measured values" button on the display.
- In the selection list, choose "positioner for the high pressure turbocharger, actual value raw tension" and keep selecting until the measured value is shown in the display.
- Connect the hand vacuum pump (VAS 6213) to the vacuum diaphragm.
- Set a voltage of 0.760 volts by generating a vacuum at a maximum of 0.65 bar while observing the shown values.
Maintain a constant vacuum and voltage of 706 mV during the subsequent adjustment procedure for the control rod.
- Slowly screw the lock nut - B - for the control rod down by hand. The adjustment lever is on the lower stop.
- Counter hold the lock nut - B - and turn the securing nut - A - on the control rod against the adjustment lever, lightly using the wrench 10 x 12 (T10423).
- Release the vacuum pressure from the vacuum diaphragm.
- Observe the displayed values, without pressure it must be set to 3000 to 3400 mV.
- Connect the socket 10 mm (T10422 A) , counter hold the locking nut - B - and tighten the bolt - A -.
Generate a vacuum of 0.65 +/- 0.05 bar at the vacuum diaphragm to ensure that the adjustment lever is at the stop. A voltage of 760 mV must be set in this process.
The voltage value is OK
- Manually press the securing plate onto the control rod and turn it 90° in the - direction of the arrow -.
- Seal the control rod/securing nut connection with sealing wax from the replacement part kit.
The 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 -.
- Counter hold the lock nut - B -, counter rotate the securing nut - A -, and tighten using the socket 10 mm (T10422 A).
- Manually press the securing plate onto the control rod and turn it 90° in the - direction of the arrow -.
- Seal the control rod/securing nut connection with sealing wax from the replacement part kit.
Continuation
- Install the cover on the turbocharger.
- Reassemble the engine.
- Start the engine and erase the Diagnostic Trouble Code (DTC) memory. Refer to the vehicle diagnostic tester.
- Check the setting as follows:
Selecting the Diagnostic Function
- Press the "006 - basic setting" button on the display.
- Select "turbocharger adaptations" in the selection list.
- In the lower right display press the "values" button.
- In the selection list, choose "Positioner for the High Pressure Turbocharger, Raw Tension Actual Value".
- In the lower right display press the "start" button.
- Observe the value in the lower window. It must fluctuate between 0.65-0.85 mV and 3000-3400 mV (vacuum diaphragm alternates between the two end positions).
If the voltage values are OK:
- End the basic setting.