Removing and installing turbocharger 1 control unit J724 - vehicles with two turbochargers, manual mode — AUDI

Removing and installing
turbocharger 1 control unit
J724
- vehicles with two turbochargers, manual mode
Special tools and workshop equipment required
Tester for E-positioner
VAS 6395
/
VAS 6395A
or
VAS 6395B
Retainer
VAS 6395 /7
Modifying retainer
VAS 6395 /7
(if necessary)
If there is already a recess
arrow
as shown in illustration
A
, no modification is necessary.
If there is no recess, modify retainer
VAS 6395 /7
as shown in illustration
B
.
Removing
Note
Observe rules for cleanliness
Chapter
.
Remove engine cover panel
Chapter
.
Remove plenum chamber partition panel
General body repairs, exterior
Rep. gr.
50
Bulkhead; Removing and installing plenum chamber partition panel
.
Release cover
3
and swivel to side
arrow
.
Connect
tester
VAS 6395
to positive terminal
2
and earth
1
with
connection lead
VAS 6395/2
.
Note
The following procedure is described for using
tester
VAS 6395 /1
/
VAS 6395 A/1
.
Depending on the equipment and tools available in your workshop,
tester
VAS 6395 B/1
may also be used.
Although the buttons are arranged in different positions, the designations/functions are the same (see illustration).
Procedure for
tester for E-positioner
VAS 6395 B/1
and
E-box
VAS 6395 A/1
:
Select software version
SW Hella
using 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
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
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 [>]
or
>1. START Bi-Turbo
2. NEXT [>]
If the following appears on the display, an incorrect software version has been loaded:
>1. TEST
2. LEARN
Note
German market: If this is the case, download the correct software version (
“Hella”
) 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 (
“Hella”
) from your Importer's information platform.
Continuation for all testers:
Unplug electrical connector for
turbocharger 1 control unit
J724
.
Connect
connection lead
VAS 6395/2
to
turbocharger 1 control unit
J724
and to
tester
VAS 6395
.
Display on
VAS 6395
:
Press
↓
button
item 6
twice to select
MANUAL
mode.
Confirm
MANUAL
mode by pressing
v
button
item 4
.
2. NEXT [>]
>3. MANUAL
Remove bolt
1
.
Note
Do NOT unscrew any of the other bolts visible in the illustration.
Fit bracket
VAS 6395 /7
on centring hole of bracket for
turbocharger 1 control unit
J724
and tighten
bolt
to 7 Nm.
Note
Centring pin on bracket
VAS 6395 /7
must engage in hole in bracket for
turbocharger 1 control unit
J724
.
Determining voltage value:
Press
↑
button
item 5
on
VAS 6395
to move coupling rod
1
onto bracket
VAS 6395 /7
.
Note
If the control unit stops moving during this process, assist it by pushing gently with your finger
arrow
.
Display on
VAS 6395
:
X.XXX V
Note down voltage value
1
.
Press
↓
button
item 6
on
VAS 6395
to move coupling rod
1
back off bracket
VAS 6395 /7
.
Repeat process for determining voltage value two more times and note down voltage values.
Note
If it is necessary to assist the control unit by pushing the coupling rod
3
with your finger in order to determine the voltage value, you must do this each time the process is repeated (try to apply the same amount of pressure)
arrow
.
Calculate average of 3 recorded voltage values.
Unclip securing clip.
Disengage coupling rod
4
at
turbocharger 1 control unit
J724
and lay coupling rod down.
Caution
Do not bend coupling rod.
Remove bolts
1, 2, 3
and dispose of them.
Note
Do NOT unscrew any of the other bolts visible in the illustration.
Remove old
turbocharger 1 control unit
J724
and dispose of it.
Install new
turbocharger 1 control unit
J724
in reverse sequence of removal.
Note
Only exchange the coupling rod from the replacement part kit if necessary (e.g. due to damage).
Fit new bolts
1, 2, 3
, M6x15 with tapered shank:
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
connecting wire
VAS 6395/2
with adapter to new
turbocharger 1 control unit
J724
.
Set new
turbocharger 1 control unit
J724
to a value 0.020 - 0.030V higher than value calculated previously.
To set voltage value, press
↑
button
item 5
or
↓
item 6
.
Display on
VAS 6395
:
X.XXX V
Insert coupling rod
3
.
Attach securing clip
2
.
The securing clip must engage audibly.
Now turn
turbocharger 1 control unit
J724
so that arm
1
rests against bracket
VAS 6395 /7
.
Tighten bolts
1, 2, 3
to 5 Nm.
Set voltage value on new
turbocharger 1 control unit
J724
as follows:
Caution
Setting the
turbocharger 1 control unit
J724
incorrectly can lead to problems with noise and/or poor driveability.
Press
↑
button
item 5
on
VAS 6395
to move coupling rod
3
onto bracket
VAS 6395 /7
.
Display on
VAS 6395
:
X.XXX V
Compare voltage value
1
with calculated average.
Note
The voltage of the new
turbocharger 1 control unit
must not differ from the average value for the old control unit by more than +/- 0.020V.
Press
↓
button
item 6
on
VAS 6395
to move coupling rod
3
back off bracket
VAS 6395 /7
.
If voltage value is not within range of tolerance:
Loosen bolts
1, 2, 3
just enough so that
turbocharger 1 control unit
J724
can be moved by applying light force.
Push
turbocharger 1 control unit
in appropriate direction and tighten bolts
1, 2, 3
to 5 Nm.
If voltage value is too high, push
turbocharger 1 control unit
downwards.
If voltage value is too low, push
turbocharger 1 control unit
upwards.
Measure voltage with new
turbocharger 1 control unit
J724
as follows:
Press
↑
button
item 5
on
VAS 6395
to move coupling rod
3
onto bracket
VAS 6395 /7
.
Display on
VAS 6395
:
X.XXX V
Compare voltage value
1
with calculated average.
Press
↓
button
item 6
on
VAS 6395
to move coupling rod
3
back off bracket
VAS 6395 /7
.
Voltage value outside range of tolerance
Re-adjust
turbocharger 1 control unit
J724
Anchor
.
Voltage value within range of tolerance
Tighten bolts
1, 2, 3
to 10 Nm.
Check voltage value again.
Display on
VAS 6395
:
X.XXX V
Voltage value outside range of tolerance
Re-adjust
turbocharger 1 control unit
J724
Anchor
.
Voltage value within range of tolerance
Remove bolt
arrow
and detach bracket
VAS 6395 /7
.
Screw bolt back in and tighten
Item
.
Adjustment is completed.
Unplug electrical connectors for
tester
VAS 6395
.
Assemble in reverse order.