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Connector PSG16 (595), sleeve replacement

Connector PSG16 (595), sleeve replacement

To remove


1. Remove the upper engine cover and undo the expansion tank cap to release any excess pressure in the cooling system.


2. Unplug the connector and detach the EGR valve from the intake manifold.


3. Clamp the EGR valve coolant hoses using 30 07 739 Hose pinch-off pliers and detach the hoses from the valve.


Important

ESD-SENSITIVE COMPONENT

Earth yourself by touching the car body before plugging in/unplugging components. Do not touch the component pins, see Removing electronic components .


4. Unplug the connector of the engine control module to which the measures apply.


Sleeve replacement.


1. Remove the cover.


2. Cut off the cable tie.

3. Remove the secondary catch.


4. Undo the sleeve catch by pressing in the extraction tool (part no. 85 80 151).


5. Pull out the cable with the sleeve.

6. Cut off the lead at the sleeve.


Note

For further information on how pins/sleeves are fitted, see Wiring harness repair .


7. If the lead is not long enough, splice it as follows:

7.1. Strip the insulation off of the leads.

7.2. Fit a shrink tube with adhesive on the line.

7.3. Fit sleeve (0.5-1.0 mm²), using the blue pliers from 86 12 939 Toolbox, wiring harness.

Note

Leads with 0.35 mm² are doubled over and crimped together at both ends.


7.4. Place the shrink tube over the sleeve.

7.5. Heat the shrink tube until it is secured.

8. Strip 4 mm of the lead's insulation.

9. Search for the connector in the spare parts catalogue/EPC to find the part number of the sleeve (cable terminal) to be used.

10. Fit a new sleeve on the lead using olive green pliers (0.35-0.75 mm²) from 86 12 939 Toolbox, wiring harness.

11. Check that the stripped lead goes through the entire clamped portion of the sleeve and that the insulation is properly clamped.


12. Press the sleeve into the connector through the seal.

13. Check that the sleeve is properly secured.

14. Check that the sleeve's depth of engagement is the same as the other sleeves in the connector.


15. Fit the secondary catch.


16. Secure the leads with a cable tie.


17. Fit the cover.

18. Use a mirror to check that the engine control module pins are straight.

Important

ESD-SENSITIVE COMPONENT

Earth yourself by touching the car body before plugging in/unplugging components. Do not touch the component pins, see Removing electronic components .



To fit


1. Plug in the engine control module connector.

2. Fit the EGR valve and plug in the connector.


3. Check the function of the remedied line by using the diagnostic tool to obtain any read values. For information on the function of the pins/sleeves, see Measurement values, control module connections PSG 16 .

4. Attach the hoses to the valve and remove the hose pinch-off pliers.

5. Screw on the expansion tank cap.

6. Fit the upper engine cover.


7. Clear all diagnostic trouble codes.

8. Carry out one driving cycle, i.e. run the car with varying engine load and engine speed for five minutes.

9. Read diagnostic trouble codes.