Q7 Service and Repair Turbo

Welcome WAYNE SMITH
Leading source of Online Diagnostic & Repair Information
Your Vehicle: 2010 Audi Q7 Quattro (4LB) V6-3.0L DSL Turbo (CATA)
Vehicle Powertrain Management Fuel Delivery and Air Induction Turbocharger Control
Module Service and Repair
Service and Repair
Turbocharger Control Module 1 (J724)
Special tools, testers and auxiliary items required
Tool for Replacing E-Positioner on Turbo (VAS 6395A) or (VAS 6395)
Wire Set (VAS 6395/2)
Bracket (VAS 6395/5)
Removing
Remove the engine cover - arrows -.

Open the cover - arrow - over the positive terminal clamp.
Connect the (VAS 6395) with the (VAS 6395/2) to the positive terminal and to the negative terminal.
Procedure for the E-box (VAS 6395/1A) :
Select the software version using the [Up Arrow] - 5 - and [Down Arrow] - 6 - buttons.
Press the v button - 4 - to confirm the software version.
In this example, Hella software - 1 - is selected.
Procedure for the E-box (VAS 6395/1) :

Check the E-positioner tester (VAS 6395 /1) software version:
Danger of damaging the turbocharger control module 1 (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. > 1. START
2. 2. NEXT [>]
If the following appears in the display, then incorrect software has been loaded:
1. >TEST
2. LEARN
If this is the case, then download the software from "Audi Service Net", "Workshop Equipment".
For both E-boxes:
Disconnect the turbocharger control module 1 connector.

Connect the (VAS 6395/2) to the turbocharger control module 1 and to the (VAS 6395 /1A).
The (VAS 6395 /1A) displays:

1. > 1. START
2. 2. NEXT [>]
Press the v button - 4 - to continue.
The (VAS 6395 /1A) checks the turbocharger control module 1 adjustment range in steps to determine if the end points are
being reached. "CHECK" appears in the display.
(VAS 6395 /1A) display:
1.
2. [OK]
If "[OK]" appears in the display, then the turbocharger control module 1 adjustment range is in order.
If "FAULT [OK]" appears in the display, tap the side of the turbocharger control module 1 housing several times with a
screwdriver handle and then touch the v button - 4 - to repeat the test.
Tighten the countersunk bolts already installed in the (VAS 6395/5) to 8 Nm.
Incorrect measurement because the (VAS 6395/5) was secured incorrectly.
Use only the countersunk bolts supplied with the bracket to secure it.
Do not loosen the bracket until the procedure is completed.

To determine the voltage, the turbocharger control module 1 will check back and forth several times between the stops.
Then the turbocharger control module 1 will go into the in installation position.
While determining the voltage, tap on the side of the turbocharger control module 1 housing with the handle of a screwdriver
until the following appears in the display:
The r (VAS 6395 /1A) displays:
1. X,XXX V
2. [[Up Arrow]][[Down Arrow]][OK]
Write down the voltage.
Specified value: 3.3 to 3.7 V.
If "FAULT [OK]" appears or if the voltage is less than 3.3 V or greater than 3.7 V, disconnect the (VAS 6395 /1A) and
repeat the entire procedure.
1. X,XXX V
Adjust the turbocharger control module 1 using the [Up Arrow] - 5 - or [Down Arrow] - 6 - buttons so that the coupling rod
is accessible for removal.
Remove the circlips - arrows - and disconnect the coupling rod.

1. X,XXX V
Adjust turbocharger control module 1 using the [Up Arrow] - 5 - or [Down Arrow] - 6 - buttons so that the bolts for
turbocharger control module 1 are accessible.
Disconnect the (VAS 6395/2) from the turbocharger control module 1.
The voltage supply for the (VAS 6395 /1A) must remain connected.
Remove the bolts - 1, 2 and 3 - and dispose of them.

Remove the old turbocharger control module 1 and dispose of it.
Make sure there are 3 insulating washers between the turbocharger control module 1 and the bracket.
Install the new turbocharger control module 1 in reverse order.

Install the new bolts as follows:
1. M6 x 15 with the narrow shaft
2. M6 x 15 with the narrow shaft
3. M6 x 15
Only tighten the bolts by hand.
The turbocharger control module 1 must contact the retaining plate without play, but it must be possible to move it by hand.
Connect the (VAS 6395/2) to the new turbocharger control module 1.

1. > 1. START
2. 2. NEXT [>]
Select "NEXT" using the [Down Arrow] button - 6 -.

The turbocharger control module 1 moves down the adjustment range.
The r (VAS 6395 /1A) displays:
1. X,XXX V
2. [OK]
If "FAULT" appears in the display, then replace the new turbocharger control module 1 again.

1.
2. [OK]

1. X.XXX V (starting up voltage)
2. [OK]
The turbocharger control module 1 moves into the installation position.
Install the coupling rod.

Installation position: Attach the thicker eye to the turbocharger control module 1 shaft.
Install the circlips - arrows -.
The circlips must engage audibly.
Gently push the turbocharger control module 1 to the rear - arrow -, just until the lever - 1 - touches the (VAS 6395/5).
Hold the turbocharger 1 control module in this position.

Tighten the bolts - 1, 2 and 3 - to 5 Nm.
The turbocharger control module 1 will move back and forth several times between the stops and will be set to the start up
voltage.
2. [OK]
If [OK] appears in the display, stop the adjustment.
If "CHECK" appears in the display, continue as follows.
Procedure, if "CHECK" Appears in the Display:
1. [<<<]
2. CHECK
or
1. [>>>]
2. CHECK
Loosen the bolts - 1, 2 and 3 - just enough so that is possible to move the turbocharger control module 1 with slight
resistance in the direction specified.
If [<<<] appears in the display, then slightly move the turbocharger control module 1 in direction of travel.
If [>>> appears in the display, slightly move the turbocharger control module 1 opposite the drive direction.

The turbocharger control module 1 will move again back and forth several times between the stops and will be set to the
start up voltage.
2. [OK]
Complete the Adjustment:

1. X,XXX V
2. [OK]
Remove the (VAS 6395/5).

The turbocharger control module 1 goes to the end points.
If "FAULT" appears in the display, then replace the new turbocharger control module 1 again.
1.
2. [OK]
The adjustment is complete.
Disconnect the (VAS 6395 /1A) connector.
Assembly is performed in reverse order.
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Welcome WAYNE SMITH

Leading source of Online Diagnostic & Repair Information

Service and Repair

Turbocharger Control Module 1 (J724)

Special tools, testers and auxiliary items required

Tool for Replacing E-Positioner on Turbo (VAS 6395A) or (VAS 6395)

Wire Set (VAS 6395/2)

Bracket (VAS 6395/5)

Remove the engine cover - arrows -.

Procedure for the E-box (VAS 6395/1A) :

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

Procedure for the E-box (VAS 6395/1) :

Danger of damaging the turbocharger control module 1 (J724).

For both E-boxes:

Disconnect the turbocharger control module 1 connector.

The (VAS 6395 /1A) displays:

Press the v button - 4 - to continue.

(VAS 6395 /1A) display:

Do not loosen the bracket until the procedure is completed.

Press the v button - 4 - to continue.

The r (VAS 6395 /1A) displays:

2. [[Up Arrow]][[Down Arrow]][OK]

Write down the voltage.

Specified value: 3.3 to 3.7 V.

The (VAS 6395 /1A) displays:

The (VAS 6395 /1A) displays:

2. [[Up Arrow]][[Down Arrow]][OK]

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

Install the new turbocharger control module 1 in reverse order.

1. M6 x 15 with the narrow shaft

2. M6 x 15 with the narrow shaft

Only tighten the bolts by hand.

Connect the (VAS 6395/2) to the new turbocharger control module 1.

Press the v button - 4 - to continue.

Select "NEXT" using the [Down Arrow] button - 6 -.

The r (VAS 6395 /1A) displays:

Press the v button - 4 - to continue.

Press the v button - 4 - to continue.

1. X.XXX V (starting up voltage)

The turbocharger control module 1 moves into the installation position.

Install the coupling rod.

Install the circlips - arrows -.

The circlips must engage audibly.

Hold the turbocharger 1 control module in this position.

1. X.XXX V (starting up voltage)

If [OK] appears in the display, stop the adjustment.

If "CHECK" appears in the display, continue as follows.

Procedure, if "CHECK" Appears in the Display:

The (VAS 6395 /1A) displays:

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

The (VAS 6395 /1A) displays:

1. X.XXX V (starting up voltage)

Complete the Adjustment:

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

Remove the (VAS 6395/5).

The turbocharger control module 1 goes to the end points.

The (VAS 6395 /1A) displays:

The adjustment is complete.

Disconnect the (VAS 6395 /1A) connector.

Assembly is performed in reverse order.