Removing and installing turbocharger 1 control unit J724 — VW

Removing and installing
turbocharger 1 control unit
J724
Special tools and workshop equipment required
E-box
VAS 6395/1
Connector cable
VAS 6395/4-2
10 mm open-end spanner, 90 mm long
VAS 6395/4-3
Removing
Remove engine cover panel
Chapter
.
Unscrew bolts
1
, but only loosen bolt
3
.
Note
Vacuum line with bracket
2
is only installed on vehicles with engine codes CASA or CASD.
Lay vacuum hose with bracket
2
aside and remove heat shield for turbocharger.
Open cover over positive terminal grip.
Connect
E-box
VAS 6395/1
with
connector cable
VAS 6395/4-2
to positive terminal grip
“+”
and to earth terminal grip
“–”
.
Procedure for
E-box
VAS 6395 /1A
:
Use buttons
↑
item
5
and
↓
item
6
to select software version.
Confirm software version with button
v
item 4
.
Note
The Hella software version
item 1
is selected in this example.
Procedure for
E-box
VAS 6395 /1
:
Checking software version of
E-box
VAS 6395 /1
:
Caution
The
turbocharger 1 control unit
J724
could be damaged.
For further procedure first check for correct software download in the
E-box
VAS 6395 /1
, to do this proceed as follows:
Indicated on display of
VAS 6395 /1
(2 seconds after connecting voltage supply) with correct software download:
> 1. START
2. NEXT [>]
Note
The following appears on display with incorrect software download:
1. >TEST
2. LEARN
In this case the correct software must be downloaded via
“Audi ServiceNet”
from the
“Workshop Equipment”
area.
Continuation for both E-boxes:
Separate electrical connector for
turbocharger 1 control unit
J724
.
Connect
connector cable
VAS 6395/2
to
turbocharger 1 control unit
J724
and to
E-box
VAS 6395 /1A
.
Indicated on display of
VAS 6395 /1A
:
> 1. START
2. NEXT [>]
To continue, press
v
button
item 4
.
E-box
VAS 6395 /1A
runs through adjustment range of
turbocharger 1 control unit
J724
in stages, and checks whether end points are reached.
“CHECK”
is shown in display.
Indicated on display of
VAS 6395 /1A
:
[OK]
Note
When
“[OK]”
is shown on display, adjustment range of
turbocharger 1 control unit
J724
is OK.
When
“FAULT [OK]”
is shown on display, tap several times on housing of
turbocharger 1 control unit
J724
using handle of a screwdriver and repeat test by pressing
v
button
item 4
.
Tighten
bracket
VAS 6395/5
with enclosed countersunk head bolts screwed into bracket to 8 Nm.
Caution
Measurement error due to improperly secured
bracket
VAS 6395/5
.
Bracket may only be tightened with enclosed countersunk head bolts.
Bracket must no longer be released until work sequence is completed.
To continue, press
v
button
item 4
.
To determine voltage value,
turbocharger 1 control unit
J724
moves back and forth between stops several times.
Turbocharger 1 control unit
J724
then moves to installation position.
Whilst determining voltage value, constantly tap on housing of
turbocharger 1 control unit
J724
with handle of screwdriver until following is shown on display:
Indicated on display of
VAS 6395 /1A
:
X.XXX V
[↑][↓][OK]
Note voltage value.
Specification: 3.3…3.7 V.
Note
When
“FAULT [OK]”
or a voltage value of less than 3.3 V or greater than 3.7 V is shown on display, disconnect
E-box
VAS 6395 /1A
and repeat entire work sequence
Anchor
.
Indicated on display of
VAS 6395 /1A
:
X.XXX V
[↑][↓][OK]
Using buttons
↑
item 5
and
↓
item 6
, adjust
turbocharger 1 control unit
J724
so that the coupling rod is accessible for removing.
Unclip and dispose of circlips
arrows
, remove coupling rod.
Indicated on display of
VAS 6395 /1A
:
X.XXX V
[↑][↓][OK]
Using buttons
↑
item
5
and
↓
item
6
, adjust
turbocharger 1 control unit
J724
so that bolts for
J724
are easily accessible.
Separate
connector cable
VAS 6395/2
from
turbocharger 1 control unit
J724
.
Caution
The voltage supply for
E-box
VAS 6395 /1A
must remain connected.
Unscrew and dispose of bolts
1, 2, 3
.
Remove old
turbocharger 1 control unit
J724
and dispose of.
Caution
Check whether the 3 insulating washers are fitted between
turbocharger 1 control unit
J724
and bracket.
Install new
turbocharger 1 control unit
J724
in reverse order.
Screw in new bolts as follows:
M6 x 15 with tapered shaft
M6 x 15 with tapered shaft
M6 x 15
Tighten bolts by hand only.
The
turbocharger 1 control unit
J724
must contact the retaining plate without play, but should even be moved by hand.
Connect
connector cable
VAS 6395/2
to new
turbocharger 1 control unit
J724
.
To continue, press
v
button
item 4
.
Indicated on display of
VAS 6395 /1A
:
> 1. START
2. NEXT [>]
Use button
↓
item
6
to select menu item
“NEXT”
.
To continue, press
v
button
item 4
.
E-box
VAS 6395 /1A
runs through adjustment range of
turbocharger 1 control unit
J724
in stages, and checks whether end points are reached.
“CHECK”
is shown in display.
Indicated on display of
VAS 6395 /1A
:
X.XXX V
[OK]
Note
When
“FAULT”
is shown on display, new
turbocharger 1 control unit
J724
must be renewed again.
To continue, press
v
button
item 4
.
Indicated on display of
VAS 6395 /1A
:
[OK]
To continue, press
v
button
item 4
.
Indicated on display of
VAS 6395 /1A
:
X.XXX V (initially determined voltage value)
[OK]
Turbocharger 1 control unit
J724
then moves to installation position.
Insert coupling rod.
Installation position: Eye with greater wall thickness is positioned on shaft of
turbocharger 1 control unit
J724
.
Position circlips
arrows
.
Circlips must audibly engage.
Press
turbocharger 1 control unit
J724
backwards without force
arrow
until lever
1
lightly contacts
bracket
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 stops several times and is set to initially determined voltage value.
Indicated on display of
VAS 6395 /1A
:
X.XXX V (initially determined voltage value)
[OK]
Note
If [OK] was shown on display, end adjustment
Anchor
.
If
“CHECK”
was shown on display, proceed as described in the following.
Procedure if
“CHECK”
is shown on display:
Indicated on display of
VAS 6395 /1A
:
[<<<]
CHECK
or
[>>>]
CHECK
Loosen bolts
1, 2, 3
just sufficiently so that
turbocharger 1 control unit
J724
can be pushed with slight resistance in specified direction:
If [<<<] is displayed, shift
J724
slightly in direction of travel.
If [>>> is displayed, shift
J724
slightly counter to direction of travel.
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 stops several times and is set to initially determined voltage value.
Indicated on display of
VAS 6395 /1A
:
X.XXX V
[OK]
Completing adjustment:
Tighten bolts
1, 2, 3
to 10 Nm.
To continue, press
v
button
item 4
.
Indicated on display of
VAS 6395 /1A
:
X.XXX V
[OK]
Unbolt
bracket
VAS 6395/5
.
To continue, press
v
button
item 4
.
Turbocharger 1 control unit
J724
moves to end points.
Note
When
“FAULT”
is shown on display, new
turbocharger 1 control unit
J724
must be renewed
Anchor
.
Indicated on display of
VAS 6395 /1A
:
[OK]
The setting is complete.
Separate electrical connectors for
E-box
VAS 6395 /1A
.
Installation is carried out in the reverse order.