SEAT Leon Workshop Service and Repair Manuals

Pressure capsule with charge pressure actuator position sender -G581-: replace Special tools and workshop equipment required

t  10 mm Socket -T10422 o T10422 A- or see equivalent → Anchor

t  Ring spanner 10x12 -T10423-, see equivalent → Anchor

t  Manual vacuum pump -VAS 6213-, see equivalent → Anchor t  Vehicle diagnosis, testing and information system   Caution The specified special tools, especially the 10 mm socket -T10422 o T10422 A-, are only intended to be used for the following work sequences described and should never be used for other screw connections. Deformation may occur when higher tightening torques are applied.   Note There is a spare part set available for replacing the pressure capsule with charge pressure actuator position sender -G581-, → ETKA (Electronic parts catalogue).

Removal: –  Open the protective mat and unplug the connector -arrow- at the side of the Position sender for charge pressure actuator -G581-.

–  Remove the connecting pipe -1- of the cylinder head cover and cylinder block ventilation; press the release tabs for this purpose. –  Free vacuum hoses -arrows-. –  Unscrew bolt -2- (captive), swing air pipe with inlet connection to rear and pull off from turbocharger. –  Seal the opening of the turbocharger using the cover of the spare part set. –  Remove the vacuum line from the pressure capsule.

–  Hold the counter nut -B- and using the 10 mm socket -T10422 o T10422 A-, remove the fixing nut of the control rod -A-.

–  Undo the fixing screws of the pressure capsule -arrows- and remove the pressure capsule along with the position sender for charge pressure positioner -G581--A-. Installation   Caution Then use new nuts and bolts from the spare part kit. –  If necessary, remove the bottom fixing nut of the control rod of the new pressure capsule. –  Screw the counter nut in the direction of the pressure capsule onto the control rod to the end by hand.

–  Guide the control rod through the adjusting lever of the turbocharger and position the pressure capsule along with the position sender for charge pressure positioner -G581--A- and tighten the fixing screws temporarily. –  Tighten securing bolts -arrows- to 8 Nm.   Note Make sure that the guide piece slides easily across the control rod.

–  Connect the plug connector -arrow- to the position sender for charge pressure positioner -G581- and attach the protective mat. –  Connecting vehicle diagnosis tester. Selecting operating mode –  Touch the pushbutton for the „vehicle self-diagnosis“ on the screen. Selecting vehicle system –  Touch the screen on „01 - Engine electronics“. The identification of the engine controller is shown on the display. Selecting diagnostic function –  Touch the pushbutton „011 - Measured values“ on the screen. –  Select „exhaust gas turbocharger high pressure actuator, actual value voltage“ from the list and continue until the measuring value is shown on the display. –  Connect the manual vacuum pump -VAS 6213- to the pressure capsule. –  When observing the indicated measuring value, adjust a voltage of 760 mV by creating a vacuum of maximum 0.65 bar.   Caution During the subsequent procedure for setting the control rod, the vacuum pressure as well as the voltage of 760 mV must be kept constant.

–  Slowly unscrew the counter nut -B- from the control rod (screw from the rod). The adjustment lever is positioned at the lower »stop«. –  Hold the fixing nut -B- tight and turn the fixing nut -A- on the control rod against the adjustment lever in the process. Tighten slightly using the ring spanner 10x12 -T10423-. –  Allow the vacuum to escape from the pressure capsule. –  Observe the measurement value displayed; when depressurised, the value should be 3000 ... 3400 mV. –  Use the 10 mm socket -T10422 o T10422 A-, secure the counter nut -B- with the and tighten the fixing nut -A-.   Caution Build up a vacuum of 0.65 ± 0,05 bar in the pressure capsule in order to check whether adjustment lever is at the »stop«. The voltage of 760 mV must be generated. Voltage value in good condition

–  Press the locking mechanism on the control rod by hand and turn by 90° -in the direction of the arrow- when possible. –  Seal the joint control rod / fixing nut with sealing paint from the spare part set. Voltage value is not correct

–  Hold the counter nut -B- tight, undo the fixing nut -A- of the control rod and correct the value by turning the counter nut -B-. –  Hold the counter nut -B- tight, counterhold the fixing nut -A- and tighten using the 10 mm socket -T10422-.

–  Press the locking mechanism on the control rod by hand and turn by 90° -in the direction of the arrow- when possible. –  Seal the joint control rod / fixing nut with sealing paint from the spare part set. Continuation –  Remove the cover of the turbocharger. –  Complete the engine. –  Turn off the engine and erase event memory → Chapter. –  Carry out adjustment as follows: Selecting diagnostic function –  Touch the pushbutton „006 - Basic setting“ on the screen. –  Select „exhaust gas turbocharger adjustment“ from the list. –  Touch the pushbutton „Measured values“ in the lower right area on the screen. –  Select „exhaust gas turbocharger high pressure actuator, actual value voltage“ from the list. –  Touch the pushbutton „Start“ in the lower right area on the screen. –  Observe the value display in the bottom window of the display; It should deviate between 650 ... 850 mV and 3000 and 3,400 mV (pressure capsule changes between the end stops) If the values are correct: –  End basic setting procedure.