Audi Q7 Turbocharger Actuator Repair

Hello, After experiencing an issue with a Q7 equipped with a BUG engine (3L V6 TDI) manufactured in 4/2006, where the piston in cylinder 4 had melted in a star shape , the exhaust valve broke, and the turbocharger was damaged as a result.
Okay, I've installed a used engine that was completely removed from an accident-damaged Q7. I've also performed an automatic transmission oil and filter change. It runs great, except for the error shown in the log.

Saturday, February 20, 2016, 2:37:21:22077 PM.
VCDS -- A VAG/VAS emulator based on Windows. Runs on Windows 10 x64.
VCDS Version: RKS 15.7.1.0
Data as of: 20150914.
http://shop.dieselschrauber.de


Vehicle Identification Number:
License Plate:



"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."
"Die Sonne scheint hell, und die Vögel zwitschern fröhlich. Ein leichter Wind weht durch die Bäume, und die Blätter rascheln leise. Es ist ein wunderschöner Tag, um draußen zu sein."


Address 01: Engine Control Module
Label file: DRV\059-907-401-ASB.clb
Control unit part number: 4L0 910 401 K. Hardware: 4L0 907 401.
Component and/or version: 3.0L V6 TDI, G001AG, 0030.
Encoding: 0011775
Operating number: WSC 00331 211 86517
VCID: 2A5F55BA85A9146E23-807E
"One error found:"

013128 - Control unit for exhaust turbocharger 1 (J724).
P3348 - 005 - elektr. Error.
Environmental conditions:
Error status: 01100101
Error priority: 0
Error frequency: 1.
Lost Count: 255
Mileage: 218,874 km
Time: 0.
Date: 2016.02.20
Time: 14:35:43

If the error is present, the AI does not display any MIL (Malfunction Indicator Lamp) or filament warnings, and the vehicle drives sluggishly. If I clear the error while the engine is running, it drives normally with power, even on the highway at 200 km/h, and there are no more errors until I restart it; then the error reappears .

Then, I installed the old actuator motor from the broken motor – the same error! The cable is fine. The valve cover test works perfectly .

Then I adjusted the stepper motor in millimeter increments by shifting the elongated holes, but the problem persists, grrr. Online, I'm reading that you need a VAS 6395/1 to perform a basic calibration on this thing! Are there any tricks to do it without?

Unfortunately, the basic settings cannot be adjusted using VCDS.

I calibrated the injectors for all 6 cylinders, which went smoothly. I also reset the DPF values; the DPF has been flushed. A new differential pressure sensor was also installed and calibrated without any issues.

"I drove a Q7, and when I start it for the first time, there's no power. The MIL (Malfunction Indicator Lamp) and the glow plug symbol aren't lit up or flashing. If I turn the engine off briefly and then start it again immediately, it then has the power it should. "
Alternatively, you can clear the error code using VCDS while the engine is running. However, the error will reappear the next time you start the engine.
Otherwise, there are no other errors.

Problem solved
Since the small VAG shop doesn't have the VAS 6395/1, the large Audi shop, where everyone is running around, does have it, but after a long wait and completely unnecessary chatter, I decided to leave it – I will never go to a large shop like that again .

Solution: I compared the VTG adjustment screw on the old motor with the new motor and found that the actuator motor was missing 2 mm before it could touch the stop. So, I extended the long holes of the mounting bracket by 3 mm, reinstalled it, connected the plug, turned on the ignition, and the motor moved towards its programmed stop (if it moves away from the stop, simply unplug and replug the connector). Then, I pushed the actuator motor until the stop lightly touched. Yay! The error is now gone, regardless of whether the engine is cold or warm, and after several starts, the error no longer appears.

Stress regarding the VAS 6395, whether it's a loaner or a car dealership where the employees probably have very little knowledge about it, because the turbocharger is sold as a complete unit. Also, the communication with me .

Have you compared these values before and after?

034,0,Charge pressure control 2
034,1,Engine speed,,Target value (idle): 720...820 RPM
034,2,Control,Actuator,Target value (idle): 20...80 %
034,3,Feedback,Actuator,Target value (idle): 19...81 %
034.4, Boost Pressure, (ACTUAL)

Previously unrecorded, just from my "saved memory."
In case of an error, no LD is generated. The motor moves, but the actual value remains unchanged.
After the error is cleared while the engine is running, the actual value follows the target value.
Tomorrow I'm going to drive the Q7 around, and I can gladly record something during the drive if needed. So far, I've driven about 160 km without any problems - 0 errors in the memory, and it pulls cleanly even after repeated acceleration-full throttle-deceleration-full throttle sequences. On Friday, the big Q7 will be picked up .
I'm not messing around with the actuator motor anymore because everything is working perfectly now!

What exactly should I measure in idle at 700-820 RPM ?