Turbocharger Control Module 1 J724

Special tools and workshop equipment required 

• Tool for Replacing E-Positioner on Turbo VAS 6395A or VAS 6395
• Wire Set VAS 6395/2
• Bracket VAS 6395/5

Removing 

-- Remove the engine cover -arrows-.

-- Open the cover -arrow- over the positive terminal clamp.

-- Connect the VAS 6395 with the VAS 6395/2 to the positive terminal and to the negative terminal.

Procedure for the E-box VAS 6395/1A:

-- Select the software version using the ↑  -5- and ↓  -6- buttons.

-- Press the v  button -4- to confirm the software version.

Procedure for the E-box VAS 6395/1:

Check the E-positioner tester VAS 6395 /1 software version:

If the correct software is loaded, the following will be displayed on the VAS 6395/1 (2 seconds after the voltage supply is connected):

1. > 1. START
2. 2. NEXT [>]

For both E-boxes: 

-- Disconnect the turbocharger control module 1 connector.

-- Connect the VAS 6395/2 to the turbocharger control module 1 and to the VAS 6395 /1A.

The VAS 6395 /1A displays:

1. > 1. START
2. 2. NEXT [>]

-- Press the v  button -4- to continue.

• The VAS 6395 /1A checks the turbocharger control module 1 adjustment range in steps to determine if the end points are being reached. "CHECK" appears in the display.

VAS 6395 /1A display:

2. [OK]

-- Tighten the countersunk bolts already installed in the VAS 6395/5 to 8 Nm.

-- Press the v  button -4- to continue.

• To determine the voltage, the turbocharger control module 1 will check back and forth several times between the stops.
• Then the turbocharger control module 1 will go into the in installation position.

-- While determining the voltage, tap on the side of the turbocharger control module 1 housing with the handle of a screwdriver until the following appears in the display:

The r VAS 6395 /1A displays:

1. X, XXX V
2. [↑][↓][OK]

-- Write down the voltage.

• Specified value: 3.3 to 3.7 V.

The VAS 6395 /1A displays:

1. X, XXX V
2. [↑][↓][OK]

-- Adjust the turbocharger control module 1 using the ↑  -5- or ↓  -6- buttons so that the coupling rod is accessible for removal.

-- Remove the circlips -arrows- and disconnect the coupling rod.

The VAS 6395 /1A displays:

1. X, XXX V
2. [↑][↓][OK]

-- Adjust turbocharger control module 1 using the ↑  -5- or ↓  -6- buttons so that the bolts for turbocharger control module 1 are accessible.

-- Disconnect the VAS 6395/2 from the turbocharger control module 1.

-- Remove the bolts -1, 2 and 3- and dispose of them.

-- Remove the old turbocharger control module 1 and dispose of it.

-- Install the new turbocharger control module 1 in reverse order. 

-- Install the new bolts as follows:

1. M6 x 15 with the narrow shaft
2. M6 x 15 with the narrow shaft
3. M6 x 15

-- Only tighten the bolts by hand.

• The turbocharger control module 1 must contact the retaining plate without play, but it must be possible to move it by hand.

-- Connect the VAS 6395/2 to the new turbocharger control module 1.

-- Press the v  button -4- to continue.

The VAS 6395 /1A displays:

1. > 1. START
2. 2. NEXT [>]

-- Select "NEXT" using the ↓  button -6-.

-- Press the v  button -4- to continue.

• The turbocharger control module 1 moves down the adjustment range.

The r VAS 6395 /1A displays:

1. X, XXX V
2. [OK]

-- Press the v  button -4- to continue.

The VAS 6395 /1A displays:

2. [OK]

-- Press the v  button -4- to continue.

The VAS 6395 /1A displays:

1. X.XXX V (starting up voltage)
2. [OK]

• The turbocharger control module 1 moves into the installation position.

-- Install the coupling rod.

• Installation position: Attach the thicker eye to the turbocharger 1 control module -J724- shaft.

-- Install the circlips -arrows-.

• The circlips must engage audibly.

-- Gently push the turbocharger control module 1 to the rear -arrow-, just until the lever -1- touches the VAS 6395/5.

-- Hold the turbocharger 1 control module in this position.

-- Tighten the bolts -1, 2 and 3- to 5 Nm.

-- Press the v  button -4- to continue.

• The turbocharger control module 1 will move back and forth several times between the stops and will be set to the start up voltage.

The VAS 6395 /1A displays:

1. X.XXX V (starting up voltage)
2. [OK]

Procedure, if "CHECK" appears in the display: 

The VAS 6395 /1A displays:

1. [<<<]
2. CHECK

or

1. [>>>]
2. CHECK

-- Loosen the bolts -1, 2 and 3- just enough so that is possible to move the turbocharger control module 1 with slight resistance in the direction specified.

• If [<<<] appears in the display, then slightly move the turbocharger control module 1 in direction of travel.
• If [>>> appears in the display, slightly move the turbocharger control module 1 opposite the drive direction.

-- Tighten the bolts -1, 2 and 3- to 5 Nm.

-- Press the v  button -4- to continue.

• The turbocharger control module 1 will move again back and forth several times between the stops and will be set to the start up voltage.

The VAS 6395 /1A displays:

1. X.XXX V (starting up voltage)
2. [OK]

Complete the Adjustment: 

-- Tighten the bolts -1, 2 and 3- to 10 Nm.

-- Press the v  button -4- to continue.

The VAS 6395 /1A displays:

1. X, XXX V
2. [OK]

-- Remove the VAS 6395/5.

-- Press the v  button -4- to continue.

• The turbocharger control module 1 goes to the end points.

The VAS 6395 /1A displays:

2. [OK]

• The adjustment is complete.

-- Disconnect the VAS 6395 /1A connector.

Assembly is performed in reverse order.