2032958/1

Technical Service Bulletin
01 Engine does not start, rough running, excess moisture found in intake piping
01 13 04 2032958/1 June 6, 2013.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A3 TDI
2010-2013
All
Not Applicable
Condition
• Engine will not start after standing in cold weather below 0°C (32°F).
• MIL may be illuminated with various induction and/or boost system faults stored in ECM.
Technical Background
Moisture from the intake air condenses and collects in the charge air cooler. At cold temperatures, this moisture
can freeze, causing blockage of the intake air system.
Production Solution
Not Applicable.
© 2013 Audi of America, Inc.
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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
Service
Install revised charge air cooler kit 1K0198803B to avoid the formation of this moisture in the boost system:
1.
Lock carrier in service position. See Repair Manual >> Group 50 in ElsaWeb.
2.
Remove radiator and radiator fan assembly.
3.
Separate A/C condenser from charge air cooler.
4.
Remove the original charge air cooler (Figure 1,
number 3) from the vehicle.
Tip: Charge air hoses can be difficult to
remove at the charge air cooler. Try separating
the hoses from the hot and cold charge air pipes
before loosening charge air cooler.
Figure 1: Charge air cooler and intake hose layout
5.
Remove the lower charge pressure hoses (Figure 1, numbers 4 and 16) and clean off any moisture or sludge.
See Repair Manual Group 21 >> Turbocharger/G-Charger >> Description and Operation >> Component
Overview in ElsaWeb.
6.
Remove cold side charge air pipe (Figure 1, number 12) and pressure hose to throttle valve (Figure 1, number
7).
7.
Separate the A/C condenser from the charge air cooler.
8.
Separate the charge air pressure sensor –G31-- from cold side charge air pipe.
© 2013 Audi of America, Inc.
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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
9.
Install charge air pressure sensor -G31- from kit to cold side charge air pipe.
10. Loosely fit the pressure hose with new temperature switch to the cold side charge air pipe.
Tip: Loosely installing pressure hose with switch to cold side charge air pipe allows for “wiggle room”
when reinstalling.
11. Install the cold side charge air pipe (Figure 1, number 12) and connect the charge air pressure sensor -G31electrical connector.
12. Note the vacuum hose routing on the temperature
switch (Figure 2).
Figure 2: Vacuum hose routing on temperature
switch, showing ventilation hose to air cleaner (1),
hose to vacuum source (2), and hose to charge air
cooler regulator flap (3).
© 2013 Audi of America, Inc.
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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
13. Route vacuum overlay harness (Figure 3, Figure 4).
Figure 3: Routing the vacuum overlay harness
Figure 4: Routing the vacuum overlay harness
14. Cut ventilation hose to air cleaner (Figure 5).
Figure 5: The red arrow indicates where to cut
ventilation hose.
© 2013 Audi of America, Inc.
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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
15. Install splice (Figure 6).
Figure 6: The red arrow indicates where to install
splice.
Tip: Note the white tracer on the vacuum hose (Figure 6).
16. Cut vacuum source hose where indicated (Figure 7)
and install splice.
Figure 7: The red arrow indicates where to cut
vacuum source hose and install splice.
17. Install the revised charge air cooler (Figure 1, number 3) with regulating flap and connect the regulating flap
vacuum hose.
18. Re-assemble all charge air pipe connections.
19. Connect A/C condenser to charge air cooler using fasteners from kit, and install radiator with fan assembly.
20. Reassemble front carrier.
21. Re-aim headlights.
© 2013 Audi of America, Inc.
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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
Warranty
Claim Type:
Use applicable claim type. If vehicle is outside any warranty, this Technical
Service Bulletin is informational only.
Service Number:
2143
Damage Code:
0055
Labor Operations:
Diagnostic Time:
Lock carrier remove+reinstall
5038 1900
220 TU
Charge air cooler remove+reinstall
2143 1962
160 TU
Temperature sensor remove+reinstall
2151 1910
70 TU
GFF
0150 0000
20 TU
Road test prior to service procedure
No Allowance 0 TU
Road test after service procedure
No Allowance 0 TU
Technical diagnosis at dealer’s discretion.
(Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance
details)
Claim Comment:
As per TSB #2032958/1
All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and
Procedures Manual. Claims are subject to review or audit by Audi Warranty.
Required Parts and Tools
Part Number
Part Description
Quantity
1K0198803B
Cold Weather Intercooler Kit
1
No special tools are required.
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with
your Parts Department and service manuals for the latest information.
© 2013 Audi of America, Inc.
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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.