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.
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2. |
Unplug the connector and detach the EGR valve from the intake manifold.
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3. |
Clamp the EGR valve coolant hoses using
30 07 739 Hose pinch-off pliers
and detach the hoses from the valve.
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4. |
Unplug the connector of the engine control module to which the measures apply.
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Sleeve replacement. |
1. |
Remove the cover.
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2. |
Cut off the cable tie.
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3. |
Remove the secondary catch.
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4. |
Undo the sleeve catch by pressing in the extraction tool (part no. 85 80 151).
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5. |
Pull out the cable with the sleeve.
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6. |
Cut off the lead at the sleeve.
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7. |
If the lead is not long enough, splice it as follows:
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7.1. |
Strip the insulation off of the leads.
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7.2. |
Fit a shrink tube with adhesive on the line.
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7.3. |
Fit sleeve (0.5-1.0 mm²), using the blue pliers from 86 12 939 Toolbox, wiring harness.
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7.4. |
Place the shrink tube over the sleeve.
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7.5. |
Heat the shrink tube until it is secured.
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8. |
Strip 4 mm of the lead's insulation.
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9. |
Search for the connector in the spare parts catalogue/EPC to find the part number of the sleeve (cable terminal) to be used.
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10. |
Fit a new sleeve on the lead using olive green pliers (0.35-0.75 mm²) from 86 12 939 Toolbox, wiring harness.
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11. |
Check that the stripped lead goes through the entire clamped portion of the sleeve and that the insulation is properly clamped.
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12. |
Press the sleeve into the connector through the seal.
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13. |
Check that the sleeve is properly secured.
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14. |
Check that the sleeve's depth of engagement is the same as the other sleeves in the connector.
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15. |
Fit the secondary catch.
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16. |
Secure the leads with a cable tie.
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17. |
Fit the cover.
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18. |
Use a mirror to check that the engine control module pins are straight.
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To fit |
1. |
Plug in the engine control module connector.
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2. |
Fit the EGR valve and plug in the connector.
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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
.
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4. |
Attach the hoses to the valve and remove the hose pinch-off pliers.
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5. |
Screw on the expansion tank cap.
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6. |
Fit the upper engine cover.
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7. |
Clear all diagnostic trouble codes.
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8. |
Carry out one driving cycle, i.e. run the car with varying engine load and engine speed for five minutes.
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9. |
Read diagnostic trouble codes.
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