Audi Workshop Service and Repair Manuals

Removing and installing turbocharger 1 control unit -J724- - vehicles with 3.0 ltr. engine Special tools and workshop equipment required t  Tester -VAS 6395/1- t  Connection lead -VAS 6395/4-2- t  Open-end spanner, 10 mm (90 mm long) -VAS 6395/4-3-

Removing Proceed as follows: –  Carefully pull engine cover panel off four retaining pins one after the other -arrows-.

–  Remove bolts -arrows- and detach heat shield for turbocharger.   Note The bottom bolt -right arrow- does not have to be completely removed.

–  Connect tester -VAS 6395/1- with connecting wire -VAS 6395/2- to positive battery terminal -arrow- and negative battery terminal.

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 -  >TEST 2 -  LEARN   Note t  If the following appears on the display, an incorrect software version has been loaded: t  1. START t  2. NEXT [>] t  If this is the case, download the correct software version from the „Audi ServiceNet“ under „Workshop Equipment“.

Continuation of procedure: –  Unplug electrical connector for turbocharger 1 control unit -J724-. –  Connect connection lead -VAS 6395/4-2- to turbocharger 1 control unit -J724- and to tester -VAS 6395/1-.

Display on -VAS 6395/1-: 1 -  >TEST 2 -  LEARN –  To continue, press v button -item 4-.

Display on -VAS 6395/1-: 1 -  CHECK 2 -  S: XX %    I: XX % l  The tester -VAS 6395/1- runs through the adjustment range of the turbocharger 1 control unit -J724- and checks the feedback of the positions.

Display on -VAS 6395/1- if turbocharger 1 control unit -J724- is OK: 1 -  ACTUATOR OK l  The test is completed. –  Unplug electrical connectors for tester -VAS 6395/1-. Assemble in reverse order.

Display on -VAS 6395/1- if turbocharger 1 control unit -J724- is not OK: 1 -  PROBLEM l  Renew turbocharger 1 control unit -J724-.

–  To do so, proceed as follows: –  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  >TEST 2 -  LEARN –  Press ↓ button -item 6-.

Display on -VAS 6395/1-: 1 -  TEST 2 -  >LEARN –  To continue, press v button -item 4-.

Display on -VAS 6395/1-: 1 -  STEP 1 –  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 coupling rod -arrows- and dispose of it.

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  STEP 2

–  Disconnect connection lead -VAS 6395/4-2- from turbocharger 1 control unit -J724-.   Caution Power supply for tester -VAS 6395/1- must remain connected.

–  Unclip retaining clip -1- for electrical wire. –  Remove bolts -arrows-; use open-end spanner, 10 mm (90 mm long) -VAS 6395/4-3- for bolts at centre and bottom. –  Remove old turbocharger 1 control unit -J724- and dispose of it. –  Install new turbocharger 1 control unit -J724- in reverse order of removal, tighten bolts -arrows- only hand-tight. l  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.

–  Clip on new coupling rod -arrows-.

–  Connect connection lead -VAS 6395/4-2- to turbocharger 1 control unit -J724-.

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  STEP 3

–  Press turbocharger 1 control unit -J724- downwards and towards rear using moderate pressure -arrow A-, at the same time tighten bolts -arrows B- to 10 Nm using open-end spanner, 10 mm (90 mm long) -VAS 6395/4-3- for centre and bottom bolts.

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  WARNING 2 -  LEARNING   Caution t  Now check correct installation of turbocharger 1 control unit -J724-; from the next step of the programme onwards (confirmed by the v button -item 4-) the turbocharger 1 control unit -J724- learns the limit positions of the adjustment travel once only. If the limit positions are not stored correctly due to an incorrect installation position, the learning procedure of turbocharger 1 control unit -J724- cannot be repeated and the control unit must be renewed. t  If you are not certain that the installation position is correct, you can terminate the procedure by pressing the x button -item 3- and the start the procedure again.

–  To confirm that the new turbocharger 1 control unit -J724- has been correctly installed, press v button -item 4-. Display on -VAS 6395/1-: 1 -  TEST 1 2 -  S: 80.0 %    I: XX % l  Specification: I = 80 %, successful learning is confirmed by the display „LEARNING“ in display zone -1-.

–  At the same time, check position of adjustment lever at turbocharger 1 control unit -J724-: l  The edge of adjustment lever -2- must be within marking -1-.

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  TEST 2 2 -  S: 16.0 %    I: XX % l  Specification: I = 16 %, successful learning is confirmed by the display „LEARNING“ in display zone -1-.

–  At the same time, check position of adjustment lever at turbocharger 1 control unit -J724-: l  The edge of adjustment lever -1- must be within marking -2-.

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  TEST 3 2 -  S: 55.0 %    I: XX % l  Check of centre position is now performed.

–  To continue, press v button -item 4-. Display on -VAS 6395/1-: 1 -  OK –  To confirm, press v button -item 4-. l  Adjustment is completed. –  Unplug electrical connectors for tester -VAS 6395/1-. Assemble in reverse order.