BV50 Actuator Replacement PDF

Removing and installing turbocharger 1 control unitJ724 - vehicles with 3.0 ltr.
engine Page 1 of 13
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.
vw-wi://rl/A.en-GB.A00.5919.89.wi::46672932.xml?xsl=3 16/10/2015
Removing and installing turbocharger 1 control unitJ724 - vehicles with 3.0 ltr. engine Page 2 of 13
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
If the following appears on the
t display, an incorrect software
version has been loaded:
t 1. START
t 2. NEXT [>]
If this is the case, download the
correct software version from the
t
„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
-.

1 - CHECK
2 - S: XX % I: XX %
The tester -VAS 6395/1- runs
through the adjustment range of the
l 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
Renew turbocharger 1 control unit
l
-J724-.
– To do so, proceed as follows:

-.
1 - >TEST
2 - LEARN
– Press ↓ button -item 6-.

1 - TEST
2 - >LEARN
-.

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.

-.
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.
Turbocharger 1 control unit -J724-
must rest on retaining plate so there
l
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-.

-.
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.
Removing and installing turbocharger 1 control unitJ724 - vehicles with 3.0 ltr. eng... Page 10 of 13

-.
1 - WARNING
2 - LEARNING
Caution
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
t 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.
If you are not certain that the
installation position is correct, you
t 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-.
1 - TEST 1
2 - S: 80.0 % I: XX %
Specification: I = 80 %, successful
learning is confirmed by the
l
display „LEARNING“ in display
zone -1-.
At the same time, check position of

–
adjustment lever at turbocharger 1
control unit -J724-:
The edge of adjustment lever -2-
l
must be within marking -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-:
The edge of adjustment lever -1-
l
must be within marking -2-.

-.
1 - TEST 3
2 - S: 55.0 % I: XX %
Check of centre position is now
l
performed.

-.
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.

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Removing and installing turbocharger 1 control unitJ724 - vehicles with 3.0 ltr.

– Remove bolts -arrows- and detach

Connect tester -VAS 6395/1- with

Checking software version of tester -

Display on -VAS 6395/1-:

Display on -VAS 6395/1-:

Display on -VAS 6395/1- if

Display on -VAS 6395/1- if

– To do so, proceed as follows:

Display on -VAS 6395/1-:

Display on -VAS 6395/1-:

– Unclip coupling rod -arrows- and

– To continue, press v button -item 4

Disconnect connection lead -VAS

– Unclip retaining clip -1- for

– Clip on new coupling rod -arrows-.

– Connect connection lead -VAS

– To continue, press v button -item 4

Press turbocharger 1 control unit -

– To continue, press v button -item 4

At the same time, check position of

– To continue, press v button -item 4

display „LEARNING“ in display

At the same time, check position of

– To continue, press v button -item 4

– To continue, press v button -item 4

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