Turbocharger Control Module: Service and Repair
Turbocharger 1 Control Module
Special tools, testers and auxiliary items required
• Tool for Replacing E-Positioner on Turbo (VAS 6395/A)
• Cable Set (VAS 6395/4-2)
• 10 mm Open End Wrench, 90 mm Long (VAS 6395/4-3)
Removing
- Carefully pull the engine cover off the 4 ball studs one after the other - arrows -.
- Remove the bolts - arrows - and the turbocharger heat shield.
• Do not remove the lower bolt - right arrow - completely.
- Open the cover over the positive terminal clamp.
- Connect the (VAS 6395/1) and the (VAS 6395/4-2) to the positive terminal clamp "+" and to the negative terminal clamp "-".
Checking the (VAS 6395/1) Software Version
CAUTION!
Danger of damaging the turbocharger 1 control module (J724).
• Make sure the correct software is loaded in the (VAS 6395/1) before performing the following procedure:
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. >TEST
2. LEARN
• If the following appears in the display, then incorrect software has been loaded:
• 1. START
• 2. NEXT
• If this is the case, then download the software from "Volkswagen ServiceNet" in the "Workshop Equipment" area.
Continuation of the Procedure
- Disconnect the turbocharger 1 control module connector.
- Connect the (VAS 6395/4-2) to the turbocharger 1 control module and to the (VAS 6395/1).
The (VAS 6395/1) displays:
1. >TEST
2. LEARN
- Press the v button - 4 - to continue.
(VAS 6395/1) display:
1. CHECK
2. S: XX % I: XX %
• The (VAS 6395/1) moves down the adjustment range for the turbocharger 1 control module in stages and checks the feedback about the positions.
Display on the (VAS 6395/1) if the Turbocharger 1 Control Module is OK
1. ACTUATOR OK
• The test ends.
- Disconnect the (VAS 6395/1) connector.
Assembly is performed in reverse order.
Display on the (VAS 6395/1) if the Turbocharger 1 Control Module is Not OK
1. PROBLEM
• The turbocharger 1 control module must be replaced.
- Perform the following steps:
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. >TEST
2. LEARN
- Press the [Down Arrow] button - item 6 -.
The (VAS 6395/1) displays:
1. TEST
2. >LEARN
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. STEP 1
- Adjust the turbocharger 1 control module using the [Up Arrow] - 5 - and the [Down Arrow] - 6 - buttons so that the coupling rod is accessible.
- Unclip the connecting rod - arrows - and dispose of it.
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. STEP 2
- Disconnect the (VAS 6395/4-2) from the turbocharger 1 control module.
CAUTION!
The voltage supply for the (VAS 6395/1) must remain connected.
- Unclip the clip - 1 - for the wire.
- Remove the bolts - arrows -. Use the (VAS 6395/4-3) for the bolts in the center and at the bottom.
- Remove the old turbocharger 1 control module and dispose of it.
- Install the new turbocharger 1 control module in the opposite sequence but only tighten the bolts - arrows - by hand.
• The turbocharger 1 control module must contact the retaining plate without play, but is must be possible to move it by hand.
- Clip in the new connecting rod - arrows -.
- Connect the (VAS 6395/4-2) to the turbocharger 1 control module.
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. STEP 3
- Press the turbocharger 1 control module back and downward firmly - arrow A - while tightening the bolts - B arrows - to 10 Nm. Use the (VAS 6395/4-3) on the bolts in the center and at the bottom.
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. WARNING
2. LEARNING
CAUTION!
• Check the turbocharger 1 control module for correct installation. The next step in the program, which is confirmed with the v button - item 4 -, the control module learns the end positions of the adjustment range one time. If the adjustment range is learned incorrectly because the installation location is incorrect, the turbocharger 1 control module cannot be programmed again and it must be replaced.
• If there are doubts as to whether it is installed correctly, the procedure can be cancelled by pressing the x button - item 3 - and started again.
- Press the v button - item 4 - to confirm that the turbocharger 1 control module was installed correctly.
(VAS 6395/1) display:
1. TEST 1
2. S: 80.0% I: XX %
• Target value: I = 80%, the "LEARNING" display in display field - 1 - confirms the programming.
- Check the position of the adjusting lever on the turbocharger 1 control module at the same time:
• The edge of adjusting lever - 2 - must be within mark - 1 -.
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. TEST 2
2. S: 16.0 % I: XX %
• Target value: I = 16%, the "LEARNING" display in display field - 1 - confirms the programming.
- Check the position of the adjusting lever on the turbocharger 1 control module at the same time:
• The edge of the adjusting lever - 1 - must be within the mark - 2 -.
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. TEST 3
2. S: 55.0 % I: XX %
• The center position is checked.
- Press the v button - 4 - to continue.
The (VAS 6395/1) displays:
1. OK
- Press the v button - item 4 - to confirm.
• The adjustment is complete.
- Disconnect the (VAS 6395/1) connector.
Assembly is performed in reverse order.