Adaptation of turbocharger in 2.7/3.0TDi AUDI

[miha99]

Anybody uses VAG CAN PRO or if anybody can recommend which device to use to calibrate 2.7 / 3.0 tdi turbo on bench?

[giuriadi]

Hello,

The procedure is:

Removing and installing turbocharger control unit 1 -J724-
Special tools and workshop equipment required
t Tester for E-positioner -VAS 6395-
t Connection lead -VAS 6395/2-
t Stop plate -VAS 6395/5-

Removing
– Remove engine cover panel -arrows-.

– Open cover -arrow- above positive terminal.
– Connect tester for E-positioner -VAS 6395- to positive terminal „+“ and negative terminal „–“ with connection lead -VAS 6395/2-.
Procedure for tester for E-positioner -VAS 6395A/1-:

– Select software version with buttons ↑-item 5- and ↓-item 6-.
– To confirm software version, press v button -item 4-.
NoteIn this example, software version Hella -item 1- is selected.
Procedure for tester for E-positioner -VAS 6395/1-:

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

Continued for both testers for E-positioner:
– Unplug electrical connector for turbocharger 1 control unit -J724-.
– Connect connection lead -VAS 6395/2- to turbocharger 1 control unit -J724- and to tester for E-positioner -VAS 6395-.

Display on -VAS 6395-:
1 - > 1. START
2 - 2. NEXT [>]
– To continue, press v button -item 4-.
l The tester for E-positioner -VAS 6395- runs through the adjustment range of the turbocharger 1 control unit -J724- and checks whether the end positions are reached; display indicates „CHECK“.

Display on -VAS 6395-:
1 -
2 - [OK]
Notet If the display indicates „[OK]“, the adjustment range of the turbocharger 1 control unit -J724- is OK.
t If the display shows „FAULT [OK]“, tap gently several times on the housing of turbocharger 1 control unit -J724- with the handle of a screwdriver and repeat the check by pressing v button -item 4-.

– Secure stop plate -VAS 6395/5- with countersunk bolts supplied with and screwed into stop plate (8 Nm).
Caution
Measurement errors due to incorrect attachment of stop plate -VAS 6395/5-.
t The stop plate should only be bolted on using the countersunk bolts supplied with the stop plate.
t The stop plate must not be loosened until the work sequence has been completed.


– To continue, press v button -item 4-.
l The turbocharger 1 control unit -J724- moves back and forth between the stops several times to determine the voltage value.
l Then the turbocharger 1 control unit -J724- moves into installation position.
– While the voltage value is being determined, keep tapping gently on the housing of turbocharger 1 control unit -J724- until the display indicates the following:
Display on -VAS 6395-:
1 - X.XXX V
2 - [↑][↓][OK]
– Note voltage value.
l Specification: 3.3 ... 3.7 V
NoteIf the display indicates „FAULT [OK]“ or the voltage is less than 3.3 V or greater than 3.7 V, unplug the tester for E-positioner -VAS 6395- and repeat the complete procedure → Anchor.

Display on -VAS 6395-:
1 - X.XXX V
2 - [↑][↓][OK]
– 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 circlips -arrows- and dispose of them, detach coupling rod.

Display on -VAS 6395-:
1 - X.XXX V
2 - [↑][↓][OK]
– By pressing buttons ↑-item 5- and ↓-item 6-, adjust turbocharger 1 control unit -J724- so that bolts for -J724- can be accessed easily.

– Disconnect connection lead -VAS 6395/2- from turbocharger 1 control unit -J724-.
Caution
Tester for E-positioner -VAS 6395- should remain connected to power supply.


– Remove bolts -1, 2, 3- and dispose of them.
– Remove old turbocharger 1 control unit -J724- and dispose of it.
Caution
Check that the three insulating washers are fitted between turbocharger 1 control unit -J724- and the bracket.

– Install new turbocharger 1 control unit -J724- in reverse sequence of removal.
– Fit new bolts as follows:
1 - M6x15 with tapered shank
2 - M6x15 with tapered shank
3 - M6x15
– Initially hand-tighten bolts.
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.

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

– To continue, press v button -item 4-.
Display on -VAS 6395-:
1 - > 1. START
2 - 2. NEXT [>]
– Select menu item „NEXT“ with ↓ button -item 6-.

– To continue, press v button -item 4-.
l The tester for E-positioner -VAS 6395- runs through the adjustment range of the turbocharger 1 control unit -J724- and checks whether the end positions are reached; display indicates „CHECK“.
Display on -VAS 6395-:
1 - X.XXX V
2 - [OK]
NoteIf the display indicates „FAULT“, the new turbocharger 1 control unit -J724- must be renewed for a second time.

– To continue, press v button -item 4-.
Display on -VAS 6395-:
1 -
2 - [OK]

– To continue, press v button -item 4-.
Display on -VAS 6395-:
1 - X.XXX V (voltage determined with first measurement)
2 - [OK]
l Turbocharger 1 control unit -J724- moves into installation position.

– Insert coupling rod.
l Installation position: The thicker eyelet is fitted onto the shaft of turbocharger 1 control unit -J724-.
– Fit circlips -arrows-.
l The circlips must engage audibly.

– Press turbocharger 1 control unit -J724- towards the rear without applying force -arrow- until lever -1- rests lightly on stop plate -VAS 6395/5-.
– Hold -J724- in this position.

– Tighten bolts -1, 2, 3- to 5 Nm.

– To continue, press v button -item 4-.
l Turbocharger 1 control unit -J724- moves back and forth between the stops several times and is adjusted to the voltage value determined with the first measurement.
Display on -VAS 6395-:
1 - X.XXX V
2 - [OK]
Notet If [OK] is indicated on display, terminate adjustment → Anchor.
t If „CHECK“ is indicated on display, proceed as follows.

Procedure if display indicates „CHECK“:
Display on -VAS 6395-:
1 - [<<<]
2 - CHECK
or
1 - [>>>]
2 - CHECK

– Loosen bolts -1, 2, 3- until turbocharger 1 control unit -J724- can just be moved by applying light force in the direction stated:
l If display indicates [<<<], move -J724- slightly in direction of travel.
l If display indicates [>>>], move -J724- slightly towards rear of vehicle.
– Tighten bolts -1, 2, 3- to 5 Nm.

– To continue, press v button -item 4-.
l Turbocharger 1 control unit -J724- again moves back and forth between the stops several times and is adjusted to the voltage value determined with the first measurement.
Display on -VAS 6395-:
1 - X.XXX V (voltage determined with first measurement)
2 - [OK]

Terminating adjustment:
– Tighten bolts -1, 2, 3- to 10 Nm.

– To continue, press v button -item 4-.
Display on -VAS 6395-:
1 - X.XXX V
2 - [OK]

– Remove stop plate -VAS 6395/5-.
– Secure electrical wiring with retaining clip -1-.

– To continue, press v button -item 4-.
l Turbocharger 1 control unit -J724- moves to end positions.
NoteIf the display indicates „FAULT“, the new turbocharger 1 control unit -J724- must be renewed → Anchor.
Display on -VAS 6395-:
1 -
2 - [OK]
l Adjustment is completed.
– Unplug electrical connectors for tester for E-positioner -VAS 6395-.
Assemble in reverse order.

[miha99]

Thank you M8, and how much does it cost this set?

[dimitar]

Thank you M8, and how much does it cost this set?

same as vas5054 original

[miha99]

And no other alternative ???

[gwr1234]

Hi cost for this is around ?500.