Turbo Boost Sensor: Service and Repair

Vacuum Diaphragm with Charge Pressure Actuator Position Sensor G581

Special tools, testers and auxiliary items required

• Socket (T40055)

• Socket 10 mm (T10422)

• Ring Spanner 10 x 12 (T10423)

• Vehicle Diagnosis Tester


The specified special tools, in particular the socket 10 mm (T10422) , are designed exclusively for use according to the following procedure and may not be used for other threaded connections. Higher torques can cause deformation.

• There is a replacement kit available for replacing the vacuum diaphragm with the charge pressure actuator position sensor. Refer to the Parts Catalog.

Removing

- Remove the air filter housing with the Mass Airflow (MAF) sensor and connecting pipe. Refer to => [ Air Filter Housing Overview ] Air Filter Housing Overview.

- Open the heat shield mat and disconnect the electrical connector - arrow - from the charge pressure actuator position sensor.






Jetta from MY 05 through 10, Jetta SportWagen (US)/Jetta Wagon (Canada) for MY 09 and Jetta SportWagen (US)/Golf Wagon (Canada) from MY 10






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

- Expose the vacuum hoses - arrows -.

- Remove the bolt - 2 - (cannot be lost) 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 11






- Expose the vacuum hoses - arrows -.

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






- Disconnect the connector - 2 -.

- Remove the bolt - 1 - (cannot be lost) 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 the warm air pipe from the guide - 2 -.






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.


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

- Prepare a 14 mm open end wrench as shown for counter holding purposes.

14 mm open end wrench for counter holding the oil supply line connection fitting





• A = 110 mm

• B = 25 mm

- Counter hold the connection with the 14 mm open end wrench, refer to => [ 14 mm open end wrench for counter holding the oil supply line connection fitting ] and remove the oil supply line - arrow - from the turbocharger using the socket (T40055).






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

Jetta from MY 11






- Set the socket 10 mm (T10422) to dimension - A -.

• A = 57 mm

Continuation for All






- Install the ring spanner 10 x 12 (T10423) - 1 - and the socket 10 mm (T10422) - 2 - with a ratchet - 3 - as illustrated.

- Counter hold the lock nut - B - with the ring spanner 10 x 12 (T10423) and unscrew the securing nut - A - with the socket 10 mm (T10422) from the control rod.






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






Installing


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 -.

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






• 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 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 and the coding for the Engine Control Module (ECM).

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.


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".






- 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 spanner 10 x 12 (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 socket 10 mm (T10422) , counter hold the lock nut - B - using the ring spanner 10 x 12 (T10423) and tighten the securing nut - A -.


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° in the - direction of the arrow -.






- 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 -.






- Counter hold the lock nut - B -, turn the securing nut - A -, and tighten using the socket 10 mm (T10422).

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






- Remove 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.