Turbocharger Control Module: 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

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.

- Press the v button - 4 - to continue.






• 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.

The (VAS 6395 /1A) displays:






1. X,XXX V

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


- 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.






The (VAS 6395 /1A) displays:






1. X,XXX V

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


- 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.






- Press the v button - 4 - to continue.






The (VAS 6395 /1A) displays:

1. > 1. START

2. 2. NEXT [>]


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

- Press the v button - 4 - to continue.






• 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.

- Press the v button - 4 - to continue.






The (VAS 6395 /1A) displays:

1.

2. [OK]


- Press the v button - 4 - to continue.






The (VAS 6395 /1A) displays:

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.






- Press the v button - 4 - to continue.






• The turbocharger control module 1 will move back and forth several times between the stops and will be set to the start up voltage.

The (VAS 6395 /1A) displays:

1. X.XXX V (starting 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:






The (VAS 6395 /1A) displays:

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.

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

- Press the v button - 4 - to continue.






• 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.

The (VAS 6395 /1A) displays:

1. X.XXX V (starting up voltage)

2. [OK]


Complete the Adjustment:






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

- Press the v button - 4 - to continue.






The (VAS 6395 /1A) displays:

1. X,XXX V

2. [OK]


- Remove the (VAS 6395/5).






- Press the v button - 4 - to continue.






• 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.

The (VAS 6395 /1A) displays:

1.

2. [OK]


• The adjustment is complete.

- Disconnect the (VAS 6395 /1A) connector.

Assembly is performed in reverse order.