Turbocharger Control Module 1 -J724-, REMOVING AND INSTALLING, VEHICLES WITH TWO TURBOCHARGER MANUAL MODES

WARNING: This page is about a different car, the 2016 Audi A6 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Turbo E-Positioner Service Kit:VAS6395 / :VAS6395A or :VAS6395B
Turbo E-Positioner Service Kit - Bracket :VAS6395 /7

Correct the Turbo E-Positioner Service Kit - Bracket :VAS6395 /7 if necessary.

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Reworking of the opening -arrow- shown in the image half -A- is not required.

-- If the opening does not exist, rework the bracket Turbo E-Positioner Service Kit - Bracket :VAS6395 /7 using a file as shown in image half -B-.

Removing

NOTE:

Follow all the guidelines for clean working conditions..

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Release the cover -3- and pivot it to the side -arrow-.

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-- Connect the Turbo E-Positioner Service Kit:VAS6395 to the positive terminal -2- and to the ground -1- using the Turbo E-Positioner Service Kit - Wire Set:VAS6395/2 .

NOTE:

The following procedure description uses the Turbo E-Positioner Service Kit - E Box:VAS6395 /1 or :VAS6395A/1

Depending on the equipment stock in the workshop, the E-Box:VAS6395 B/1 can also be used.

The button positions are arranged differently, but the labels and functions are the same. (See image)

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Procedure for E-Box:VAS6395 B/1 and E-Box: VAS6395A/1 :

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

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

NOTE:

In this example, Hella software version -1- is selected.

Procedure for the Turbo E-Positioner Service Kit - E-Box:VAS6395A/1 :

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Software Version of the Tester for E-Positioner - E-Box:VAS6395B/1 , Checking:

CAUTION:

Danger of damaging the Turbocharger Control Module 1 -J724-.

Before continuing with the work procedure, check if the correct software is loaded in the Tester for E-Positioner - E-Box:VAS6395B/1 by proceeding as follows:

If the correct software is loaded, the following will be displayed on the Tester for E-Positioner - E-Box :VAS6395B/1 (two seconds after the voltage supply is connected):

>1. START
2. NEXT [>]

>1. START Bi-Turbo

2. NEXT [>]

If the following appears in the display, then incorrect software has been loaded:

>1. TEST
2. LEARN

NOTE:

German market: In this case, download the correct "Hella" software from the "Audi Dealer Portal under Service" in the "Workshop Equipment" section.

Rest of World: In this case, download the correct "Hella" software from the "information platform of the importer".

Procedure for all E-boxes

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-- Disconnect the Turbocharger Control Module 1 -J724- connector.

-- Connect the Connection Cable:VAS6395A/2 to the Turbocharger Control Module 2 -J724- and to the Turbo E-Positioner Service Kit:VAS6395 .

Display on the Turbo E-Positioner Service Kit:VAS6395 :

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-- Push the button ↓ -item 6- two times, so that the MANUAL mode is selected.

-- Confirm the MANUAL mode with the v button -item 4-.

2. NEXT [>]
>3. MANUAL

-- Remove the bolt -1-.

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NOTE:

The other bolts visible in the illustration must not be removed.

-- Attach the Turbo E-Positioner Service Kit - Bracket :VAS6395 /7 to the center opening in the bracket for the Turbocharger Control Module 1 -J724- and tighten the bolt to -arrow- 7 Nm.

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NOTE:

The centering pins on the bracket :VAS6395 /7 must engage in the bracket opening for the Turbocharger Control Module 1 -J724-.

Determine the voltage value:

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-- Bring up the coupling rod -1- by pressing the button ↑ -item 5- on the Turbo E-Positioner Service Kit :VAS6395 on the Turbo E-Positioner Service Kit - Bracket :VAS6395 /7 .

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NOTE:

If the control unit remains stationary when operating, support it with light finger pressure -arrow-.

Display on the Turbo E-Positioner Service Kit:VAS6395 :

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X, XXX V

-- Note the voltage value -1-.

-- Drive back the coupling rod -1- by pressing the button ↓ -item 6- on the Turbo E-Positioner Service Kit :VAS6395 from the Turbo E-Positioner Service Kit - Bracket : VAS6395 /7 .

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-- Determine the "voltage value" step, repeat it two times and note the voltage value.

NOTE:

To determine the voltage value the control module must be supported using the finger pressure, for each repeat of the coupling rod -3-, must be supported with the same finger pressure -arrow-.

-- Determine the average from the three notes measured values.

-- Unclip the lock washer.

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-- Disengage the coupling rod -4- from the Turbocharger Control Module 1 - J724- and move downward.

CAUTION:

Do not bend the coupling rod.

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

NOTE:

The other bolts visible in the illustration must not be removed.

-- Remove the old Turbocharger Control Module 1 -J724- and dispose of it.

-- Install the new Turbocharger Control Module 1 -J724- in reverse order of removal.

NOTE:

Only change the coupling rod that is present in the replacement part kit if necessary.

-- Install the new M6 x 15 bolts -1, 2 and 3- with the narrow shaft.

-- Only tighten the bolts by hand.

The Turbocharger Control Module 1 -J724- must contact the retaining plate without play, but it must be possible to move it by hand.

-- Connect the Turbo E-Positioner Service Kit - Wire Set:VAS6395/2 with the adapter to the Turbocharger Control Module 1 -J724-

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-- Adjust the new Turbocharger Control Module 1 -J724- to + 0.020V - 0.030V to the previous determined value.

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To adjust the voltage value, press the button ↑ -item 5- or ↓ -item 6-.

Display on the Turbo E-Positioner Service Kit:VAS6395 :

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X, XXX V

-- Insert the coupling rod -3-.

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-- Install the lock washer -2-.

The lock washer must engage audibly.

-- Not turn the Turbocharger Control Module 1 -J724- so that the lever -1- contacts the Turbo E-Positioner Service Kit - Bracket :VAS6395/7 .

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

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Adjust the voltage value as follows on the new Turbocharger Control Module 1 -J724-.

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CAUTION:

An incorrectly adjusted Turbocharger Control Module 1 - J724- can cause noises and handling complaints.

-- Bring up the coupling rod -3- by pressing the button ↑ -item 5- on the Turbo E-Positioner Service Kit :VAS6395 on the Turbo E-Positioner Service Kit - Bracket :VAS6395 /7 .

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Display on the Turbo E-Positioner Service Kit:VAS6395 :

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X, XXX V

-- Compare the voltage value -1- to determine the average.

NOTE:

The voltage value of the new Turbocharger Control Module 1 must not differ more than +/- 0.020V from the average of the old control module.

-- Drive back the coupling rod -3- by pressing the button ↓ -item 6- on the Turbo E-Positioner Service Kit :VAS6395 from the Turbo E-Positioner Service Kit - Bracket : VAS6395 /7 .

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Voltage value outside of the tolerance range:

-- Loosen the screws -1, 2 and 3- just enough so that is possible to move the Turbocharger Control Module 1 -J724- with slight resistance.

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-- Move the Turbocharger Control Module 1 -- according to the variation directions, tighten the bolts -1, 2 and 3- to 5 Nm.

Voltage value to high, push the Turbocharger Control Module 1 -- downward.
Voltage value to low, push the Turbocharger Control Module 1 -- upward.

Determine the voltage value with the new Turbocharger Control Module 1 -J724-.

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-- Bring up the coupling rod -3- by pressing the button ↑ -item 5- on the Turbo E-Positioner Service Kit :VAS6395 on the Turbo E-Positioner Service Kit - Bracket :VAS6395 /7 .

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Display on the Turbo E-Positioner Service Kit:VAS6395 :

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X, XXX V

-- Compare the voltage value -1- to determine the average.

-- Drive back the coupling rod -3- by pressing the button ↓ -item 6- on the Turbo E-Positioner Service Kit :VAS6395 from the Turbo E-Positioner Service Kit - Bracket : VAS6395 /7 .

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Voltage value outside of the tolerance range

-- Adjust the Turbocharger Control Module 1 -J724- again. Refer to Turbocharger Control Module 1 -J724-, REMOVING AND INSTALLING, VEHICLES WITH TWO TURBOCHARGER MANUAL MODES .

Tolerance range without tension

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

-- Check the voltage value again.

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Display on the Turbo E-Positioner Service Kit:VAS6395 :

X, XXX V

Voltage value outside of the tolerance range

-- Adjust the Turbocharger Control Module 1 -J724- again. Refer to Turbocharger Control Module 1 -J724-, REMOVING AND INSTALLING, VEHICLES WITH TWO TURBOCHARGER MANUAL MODES .

Tolerance range without tension

-- Remove the bolt -arrow- and remove the bracket :VAS6395 /7 .

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-- Re-install the bolt and tighten step go to step -5- OVERVIEW - TURBOCHARGER, VEHICLES WITH TWO TURBOCHARGERS List Item:Bolt.

The adjustment is complete.

-- Disconnect the connector for the Turbo E-Positioner Service Kit:VAS6395 .

Assembly is performed in reverse order.