Removing and installing turbocharger 1 control unit J724 — AUDI

Removing and installing
turbocharger 1 control unit
J724
Special tools and workshop equipment required
Tester for E-positioner
VAS 6395
Connection lead
VAS 6395/2
Stop plate
VAS 6395/5
Removing
Remove engine cover panel
arrows
.
Open cover
arrow
above positive terminal.
Connect
tester for E-positioner
VAS 6395
to positive terminal
“+”
and negative terminal
“–”
with
connection lead
VAS 6395/2
.
Procedure for
tester for E-positioner
VAS 6395A/1
:
Select software version with buttons
↑
item 5
and
↓
item 6
.
To confirm software version, press
v
button
item 4
.
Note
In this example, software version Hella
item 1
is selected.
Procedure for
tester for E-positioner
VAS 6395/1
:
Checking software version of
tester for E-positioner
VAS 6395/1
:
Caution
Risk of damage to
turbocharger 1 control unit
J724
.
Before continuing, check whether the correct software version is loaded in the
tester for E-positioner
VAS 6395/1
. To do so, proceed as follows:
Display on
VAS 6395/1
(2 seconds after connecting to power supply) if correct software version is loaded:
> 1. START
2. NEXT [>]
Note
If the following appears on the display, an incorrect software version has been loaded:
1. >TEST
2. LEARN
German market: If this is the case, download the correct software version from the
“Audi Partner Portal (under Service)”
in the section
“Workshop Equipment”
.
Rest of the world: If this is the case, download the correct software version from your Importer's information platform.
Continued for both
testers for E-positioner
:
Unplug electrical connector for
turbocharger 1 control unit
J724
.
Connect
connection lead
VAS 6395/2
to
turbocharger 1 control unit
J724
and to
tester for E-positioner
VAS 6395
.
Display on
VAS 6395
:
> 1. START
2. NEXT [>]
To continue, press
v
button
item 4
.
The
tester for E-positioner
VAS 6395
runs through the adjustment range of the
turbocharger 1 control unit
J724
and checks whether the end positions are reached; display indicates
“CHECK”
.
Display on
VAS 6395
:
[OK]
Note
If the display indicates
“[OK]”
, the adjustment range of the
turbocharger 1 control unit
J724
is OK.
If the display shows
“FAULT [OK]”
, tap gently several times on the housing of
turbocharger 1 control unit
J724
with the handle of a screwdriver and repeat the check by pressing
v
button
item 4
.
Secure
stop plate
VAS 6395/5
with countersunk bolts supplied with and screwed into stop plate (8 Nm).
Caution
Measurement errors due to incorrect attachment of
stop plate
VAS 6395/5
.
The stop plate should only be bolted on using the countersunk bolts supplied with the stop plate.
The stop plate must not be loosened until the work sequence has been completed.
To continue, press
v
button
item 4
.
The
turbocharger 1 control unit
J724
moves back and forth between the stops several times to determine the voltage value.
Then the
turbocharger 1 control unit
J724
moves into installation position.
While the voltage value is being determined, keep tapping gently on the housing of
turbocharger 1 control unit
J724
until the display indicates the following:
Display on
VAS 6395
:
X.XXX V
[↑][↓][OK]
Note voltage value.
Specification: 3.3 … 3.7 V.
Note
If the display indicates
“FAULT [OK]”
or the voltage is less than 3.3 V or greater than 3.7 V, unplug the
tester for E-positioner
VAS 6395
and repeat the complete procedure
Anchor
.
Display on
VAS 6395
:
X.XXX V
[↑][↓][OK]
By pressing buttons
↑
item 5
and
↓
item 6
, adjust
turbocharger 1 control unit
J724
so that coupling rod can be accessed easily for removal.
Unclip circlips
arrows
and dispose of them, detach coupling rod.
Display on
VAS 6395
:
X.XXX V
[↑][↓][OK]
By pressing buttons
↑
item 5
and
↓
item 6
, adjust
turbocharger 1 control unit
J724
so that bolts for
J724
can be accessed easily.
Disconnect
connection lead
VAS 6395/2
from
turbocharger 1 control unit
J724
.
Caution
Tester for E-positioner
VAS 6395
should remain connected to power supply.
Remove bolts
1, 2, 3
and dispose of them.
Remove old
turbocharger 1 control unit
J724
and dispose of it.
Caution
Check that the three insulating washers are fitted between
turbocharger 1 control unit
J724
and the bracket.
Install new
turbocharger 1 control unit
J724
in reverse sequence of removal.
Fit new bolts as follows:
M6x15 with tapered shank
M6x15 with tapered shank
M6x15
Initially hand-tighten bolts.
Turbocharger 1 control unit
J724
must rest on retaining plate so there is no play; it must still be possible to move control unit by hand.
Connect
connection lead
VAS 6395/2
to new
turbocharger 1 control unit
J724
.
To continue, press
v
button
item 4
.
Display on
VAS 6395
:
> 1. START
2. NEXT [>]
Select menu item
“NEXT”
with
↓
button
item 6
.
To continue, press
v
button
item 4
.
The
tester for E-positioner
VAS 6395
runs through the adjustment range of the
turbocharger 1 control unit
J724
and checks whether the end positions are reached; display indicates
“CHECK”
.
Display on
VAS 6395
:
X.XXX V
[OK]
Note
If the display indicates
“FAULT”
, the new
turbocharger 1 control unit
J724
must be renewed for a second time.
To continue, press
v
button
item 4
.
Display on
VAS 6395
:
[OK]
To continue, press
v
button
item 4
.
Display on
VAS 6395
:
X.XXX V (voltage determined with first measurement)
[OK]
Turbocharger 1 control unit
J724
moves into installation position.
Insert coupling rod.
Installation position: The thicker eyelet is fitted onto the shaft of
turbocharger 1 control unit
J724
.
Fit circlips
arrows
.
The circlips must engage audibly.
Press
turbocharger 1 control unit
J724
towards the rear without applying force
arrow
until lever
1
rests lightly on
stop plate
VAS 6395/5
.
Hold
J724
in this position.
Tighten bolts
1, 2, 3
to 5 Nm.
To continue, press
v
button
item 4
.
Turbocharger 1 control unit
J724
moves back and forth between the stops several times and is adjusted to the voltage value determined with the first measurement.
Display on
VAS 6395
:
X.XXX V
[OK]
Note
If [OK] is indicated on display, terminate adjustment
Anchor
.
If
“CHECK”
is indicated on display, proceed as follows.
Procedure if display indicates
“CHECK”
:
Display on
VAS 6395
:
[<<<]
CHECK
or
[>>>]
CHECK
Loosen bolts
1, 2, 3
until
turbocharger 1 control unit
J724
can just be moved by applying light force in the direction stated:
If display indicates [<<<], move
J724
slightly in direction of travel.
If display indicates [>>>], move
J724
slightly towards rear of vehicle.
Tighten bolts
1, 2, 3
to 5 Nm.
To continue, press
v
button
item 4
.
Turbocharger 1 control unit
J724
again moves back and forth between the stops several times and is adjusted to the voltage value determined with the first measurement.
Display on
VAS 6395
:
X.XXX V (voltage determined with first measurement)
[OK]
Terminating adjustment:
Tighten bolts
1, 2, 3
to 10 Nm.
To continue, press
v
button
item 4
.
Display on
VAS 6395
:
X.XXX V
[OK]
Remove
stop plate
VAS 6395/5
.
Secure electrical wiring with retaining clip
1
.
To continue, press
v
button
item 4
.
Turbocharger 1 control unit
J724
moves to end positions.
Note
If the display indicates
“FAULT”
, the new
turbocharger 1 control unit
J724
must be renewed
Anchor
.
Display on
VAS 6395
:
[OK]
Adjustment is completed.
Unplug electrical connectors for
tester for E-positioner
VAS 6395
.
Assemble in reverse order.