TSB-23-15-35

SB-10058586-4096
Technical Service Bulletin
23 MIL on, rough running, no start (DTCs P0087, P0088, and/or P0191) (TDI only)
23 15 35 2036668/3 June 30, 2015. Supersedes Technical Service Bulletin Group 01 number 14-75 dated March
20, 2014 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A3
2013, 2015
All
TDI clean diesel
Q5
2016
All
TDI clean diesel
Q7
2013 - 2015
All
TDI clean diesel
A8
2013, 2016
All
TDI clean diesel
Condition
REVISION HISTORY
Revision
Date
Purpose
3
-
Revised header data (Removed model years 2009 - 2012; added model years 2015 2016)
Revised title (Updated service number)
2
3/20/2014
Revised title
Revised Technical Background (Updated information)
Revised Service (Updated Tip at end of section)
1
03/06/14
Initial publication
• MIL on.
• No start or rough running.
• One or more of the following DTCs is stored in the engine control module, J623 (address word 01):
• DTC P0087 (Fuel Rail/System Pressure - Too Low)
• DTC P0088 (Fuel Rail/System Pressure - Too High)
• DTC P0191 (Fuel Rail Pressure Sensor "A" Circuit Range/Performance)
Technical Background
When diagnosing a MIL on, no-start, or rough running concern on a common rail diesel vehicle, and no root cause
is found after checking all other components and following all GFF diagnostic procedures, it may be necessary to
check for metallic particles in the High Pressure Fuel Pump.
© 2015 Audi of America, Inc.
Page 1 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Production Solution
No production change required.
Service
Note:
Removing the N290 fuel metering valve to inspect for metallic particles should only be considered as a last step
after all GFF diagnostic procedures have been performed, including testing supply volume to the high pressure
fuel pump (low pressure side) and checking for internal leakage from the injectors and N276 pressure regulating
valve.
Note:
Before the N290 fuel metering valve is removed, the area
surrounding the valve (Figure 1) must be sprayed with a
cleaner and dried with compressed air to ensure that all
debris is removed from the area.
Fuel system components may be damaged if any debris
enters the fuel system.
Figure 1. Area surrounding the valve.
1. Remove the N290 fuel metering valve and inspect the
valve and valve bore for the presence of metallic
particles (Figure 2). Proceed with the appropriate
section below.
Figure 2. Fuel metering valve and valve bore with
metallic particles (A), and without metallic particles (B).
© 2015 Audi of America, Inc.
Page 2 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
If metallic particles are found on the N290 fuel metering valve or in the valve bore:
1. Contact the Audi Technical Assistance Center (TAC)
and open a TAC ticket before continuing with the
repair. Before contacting TAC, attach the following to
the TAC ticket:
• GFF diagnostic log
• Clear pictures showing the metallic particles in the
N290 fuel metering valve and bore (Figure 3 and
Figure 4).
Figure 3. Example of a clear picture showing the
metallic particles in the N290 fuel metering valve.
Figure 4. Example of a clear picture showing the
metallic particles in the valve bore.
Note:
If a fuel system replacement is necessary, ensure that the fuel injector return line is properly seated and
sealed once installed. Inspect for seepage at the fuel injector return line connector after the test drive. If
seepage is found, the condition must be corrected.
Tip: Be sure to include the 7-digit technical service bulletin number in the repair order comments.
© 2015 Audi of America, Inc.
Page 3 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
If metallic particles are not found on the N290 fuel metering valve or in the valve bore:
1. Do NOT replace the high pressure fuel pump.
Note:
To prevent fuel system damage, ensure that the N290
fuel metering valve is free of contaminants before
reinstalling.
Additionally, ensure that neither O-ring (Figure 5) is
damaged. If either O-ring is damaged, replace the
high fuel pressure pump.
To prevent damaging the O-rings when reinstalling
the N290 fuel metering valve, lubricate them with
diesel fuel.
Figure 5. N290 fuel metering valve O-rings.
2. Use light pressure to reinstall the N290 fuel metering valve into the valve bore.
3. Install and hand tighten both M5 fasteners, ensuring that the threads are clean and dry. Pre-tighten to 2 Nm,
then to 6.5 – 7 Nm.
4. Use a paint marker or equivalent to mark the top of
the N290 fuel metering valve with a white dot (Figure
6).
Figure 6. White dot on N290 fuel metering valve.
4. Continue with diagnosis.
© 2015 Audi of America, Inc.
Page 4 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Tip: Be sure to include the 7-digit technical service bulletin number in the repair order comments.
All TDI clean diesel high pressure fuel pumps that have been replaced in conjunction with this Technical
Service Bulletin will be requested for return. These replacement parts will be reviewed to verify the presence of
metallic particles on the N290 metering valve and within the bore to ensure that the submitted part matches
the information submitted with the ATA.
Warranty
This bulletin is informational only, and is not applicable to any Audi warranty.
Additional Information
All parts and service references provided in this TSB (2036668) are subject to change and/or removal. Always
check with your Parts Department and service manuals for the latest information.
© 2015 Audi of America, Inc.
Page 5 of 5
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.