Replacing vacuum unit with position sender for charge pressure positionerG581 Page 1 of 6

     
Replacing vacuum unit with position sender
for charge pressure positioner -G581-
  Note
Hexagon key, extension 10 mm -T10422 A- repalces the old
Hexagon key, extension 10 mm -T10422-. Existing keys without
index »A« can still be used.
Special tools and workshop equipment required
  
   Hexagon key, extension 10 mm -T10422-
or Hexagon key, extension 10 mm -T10422
A-

   Ring spanner 10x12 -T10423-   

   Hand vacuum pump -VAS 6213-   

   Vehicle diagnosis tester

Caution
The special tools indicated, in particular
the Hexagon key, extension 10 mm -
T10422- or Hexagon key, extension 10
mm -T10422 A-is designed solely for use
according to the following work

vw-wi://rl/V.en-GB.K00.5905.13.wi::48347388.xml?xsl=3 26/01/2015
Replacing vacuum unit with position sender for charge pressure positionerG581 Page 2 of 6

instructions and must not be used for

other threaded connections. There is a
danger of deformation if high torques
are applied.

  Note
In order to replace the vacuum unit with
position sender for charge pressure positioner,
-G581- a spare-parts kit is available → ETKA 
(Electronic parts catalogue).
Removing

  
–   Open heat-protection mat and disconnect
electrical connector -arrow- at position
sender for charge pressure positioner -
G581-.

  
–   Remove crankcase breather connecting
pipe-1- from cylinder head cover; press
release buttons to do this.
–   Free vacuum hoses -arrows-.
–   Unscrew bolt -2- (captive), swing air pipe
with inlet connection to rear and pull off
from turbocharger.
–   Seal opening in turbocharger with the
sealing cap from the spare-parts kit.
–   Pull off vacuum line on the vacuum unit.

  
–   Counterhold lock nut -B- and unscrew

vw-wi://rl/V.en-GB.K00.5905.13.wi::48347388.xml?xsl=3 26/01/2015
Replacing vacuum unit with position sender for charge pressure positionerG581 Page 3 of 6

securing nut -A- from the control rod with

Hexagon key, extension 10 mm -T10422-
or Hexagon key, extension 10 mm -T10422
A-.

  
–   Unscrew securing bolts of the vacuum unit
-arrows- and remove the vacuum unit with
position sender for charge pressure
positioner -G581--A-
Installing

Caution
Only use new bolts and nuts from the
spare-parts kit!

–   If necessary, remove lower securing nut of

the control rod from the new vacuum unit.
–   Screw locknut by hand onto the control rod
as far as possible in the direction of the
vacuum unit.

  
–   Push control rod through the adjusting
lever, fit vacuum unit with position sender
for charge pressure positioner -G581--A-
and tighten fastening bolts.
–   Tighten securing bolts -arrows- to 8 Nm.

  Note
Make sure that the guiding element moves
easily along the control rod.

  
–   Connect connector -arrow- to the position
sender for the charge pressure positioner -

vw-wi://rl/V.en-GB.K00.5905.13.wi::48347388.xml?xsl=3 26/01/2015
Replacing vacuum unit with position sender for charge pressure positionerG581 Page 4 of 6

G581- and close the heat protection mat.

–   Connect vehicle diagnosis tester.
Selecting operating mode:
–   Click the „Vehicle self-diagnosis“ button on
the display.
Selecting vehicle system:
–   Press button „01 - Engine electronics“ on
display.
The display shows the identification of the
engine control unit.
Select diagnostic function:
–   Click the „011 - Measured values“ button
on the display.
–   In the selection list, select „Positioner for
high pressure turbocharger, actual raw
voltage“ and switch until measured value is
displayed.
–   Connect hand vacuum pump -VAS 6213-
to vacuum unit.
–   Set voltage of 760 mV by generating
maximum 0.65 bar partial vacuum while
observing the displayed measured value.

Caution
During the following procedure for
adjusting the control rod, keep the
partial vacuum and thus the voltage of
760 mV constant.
  
–   Slowly screw the locknut-B- of the control
rod downwards by hand. Adjusting lever is
resting on the lower »stop«.
–   Counterhold locknut-B- and screw securing
nut-A- onto the control rod towards the
adjusting lever. Tighten slightly with a ring
spanner 10x12 -T10423-.
–   Allow partial vacuum to escape from the
vacuum unit.
–   Observe displayed measured value; value
at normal pressure should be set at
3000 … 3400 mV.
–   Fit Hexagon key, extension 10 mm -
T10422- or Hexagon key, extension 10 mm
-T10422 A-, counterhold locknut -B- and
tighten securing nut -A-.

Caution
Cause a partial vacuum of 0.65 ± 0.05 bar 
to act on the vacuum unit in order to

vw-wi://rl/V.en-GB.K00.5905.13.wi::48347388.xml?xsl=3 26/01/2015
Replacing vacuum unit with position sender for charge pressure positionerG581 Page 5 of 6

ensure that the adjusting lever rests

against the »stop«. When this is done,
the voltage should automatically be set
to 760 mV.

Voltage OK.
  
–   Press locking plate by hand onto the
control rod and, if possible, turn 90° in the -
direction of the arrow-.
–   Seal connection between control rod and
securing nut with sealing paint from the
spare-parts kit.
Voltage not OK.

  
–   Counterhold locknut -B-, undo securing nut
-A- of the control rod and correct the
voltage by turning the locknut -B-.
–   Counterhold locknut -B-, turn securing nut -
A- in opposing direction and tighten it with
Hexagon key, extension 10 mm -T10422-
or Hexagon key, extension 10 mm -T10422
A-.

  
–   Press locking plate by hand onto the
control rod and, if possible, turn 90° in the -
direction of the arrow-.
–   Seal connection between control rod and
securing nut with sealing paint from the
spare-parts kit.
Continuation
–   Remove sealing cap from turbocharger.
–   Complete the engine.
–   Start motor and delete event memory
→ Vehicle diagnosis tester.

vw-wi://rl/V.en-GB.K00.5905.13.wi::48347388.xml?xsl=3 26/01/2015
Replacing vacuum unit with position sender for charge pressure positionerG581 Page 6 of 6

–   Check setting as follows:

Select diagnostic function:
–   Click the „006 - Basic setting“ button on the
display.
–   Select „Adaption of turbocharger“ from
selection list.
–   Click the „Measured values“ button on the
bottom right on the display.
–   Select „Positioner for high pressure
turbocharger, actual raw voltage“ from
selection list.
–   Click the „Start“ button on the bottom right
on the display.
–   Observe the value in the lower screen
window; it must fluctuate between 650 ...
850 mV and 3,000 ... 3,400 mV (vacuum
unit is move to both end stops alternately).
If voltage values OK:
–   End basic setting procedure.

vw-wi://rl/V.en-GB.K00.5905.13.wi::48347388.xml?xsl=3 26/01/2015