A191676 2036167_
Service Bulletin Details
Public Details for: A191676 2036167_
This bulletin provides instructions for a slow coolant leak from coolant connections.
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19 Coolant pipe seepage on turbocharger 19 16 76 2036167/5 December 6, 2016. Supersedes Technical Service Bulletin Group 19 number 16-75 dated October 19, 2016 for reasons listed below. Model(s) Year VIN Range Vehicle-Specific Equipment A8, S6, S7, S8, RS 7 2013 - 2017 All 4.0 T Condition REVISION HISTORY Revision Date Purpose 5 - Revised header data (Added multiple vehicles and model years) 4 10/19/2016 Revised Service (Removed S6/S7 MY13 SVM code) 3 10/04/2016 Revised Required Parts and Tools (Updated part numbers) Revised Service (Added SVM code) Revised header data (Added model year and removed VIN break) Customer concern states one of the following conditions: The low coolant level light is illuminated The coolant level is too low A black crust is visible on the turbocharger coolant lines Page 1 of 9 © 2016 Audi of America, Inc. 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 Background There may be slow coolant loss from the connections at the coolant feed pipe and the coolant return pipe. High temperatures cause the coolant to become encrusted on the connection flange of the turbocharger (Figure 1). Figure 1. Black, encrusted coolant residue (outlined area), coolant feed pipe (A), oil feed pipe (B), and coolant return pipe (C). The resulting heat after switching off the engine can, under special operating conditions, lead to very high temperatures on the coolant seals of the turbocharger. This can damage the O-ring. Production Solution Optimized temperature-resistant O-rings on the coolant connection of the turbocharger together with an extended operating period of the auxiliary cooling pump after switching off the engine. Page 2 of 9 © 2016 Audi of America, Inc. 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. Service Replace the respective O-rings on the coolant supply and return pipes according to the table listed below: Coolant line position Part number of coolant Part number of pipe optimized O-ring Size of O-ring / thickness Cylinder bank 2, supply 079145909F WHT006335A 2.0 mm (blue) WHT006335A 2.0 mm (blue) WHT006335A 2,0 mm (blue) WHT006335A 2.0 mm (blue) WHT006537 2.8 mm (black) WHT006537 2.8 mm (black) WHT006537 2.8 mm (black) WHT006537 2.8 mm (black) Original pipe Cylinder bank 1, supply 079145910F Original pipe Cylinder bank 2, return 079145947E Original pipe Cylinder bank 1, return 079145948F Original pipe Cylinder bank 2, supply 079145909H Replacement pipe Cylinder bank 1, supply 079145910H Replacement pipe Cylinder bank 2, return 079145947G Replacement pipe Cylinder bank 1, return 079145948H Replacement pipe Note: The O-ring assignment can be based on one part number on the coolant pipes, as there is no mixed installation allowed. The original coolant pipes had a 2.5 mm O-ring groove which require the 2.0 mm (blue) Orings. The later/replacement coolant pipes had larger 3.5 mm groove which require the 2.8 mm (black) O-rings. Special tool 3371 can be used to measure the thickness of the O-ring groove to determine the correct O-ring fitment. Replacing the coolant pipes is not allowed! For the replacement of the two O-rings for the coolant supply pipes we recommend the following pipe position to allow access to remove and replace the O-rings (Figure 2). Page 3 of 9 © 2016 Audi of America, Inc. 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. Figure 2. Recommended pipe position. 1. Clean the intake ports for the coolant pipes on the top of the turbochargers, the ports should be clean and dry before installing the coolant pipes with the O-rings. The new O-rings are coated with a lubricating agent and should be installed dry. 2. Replace the oil feed pipe O-rings. Coat lightly with clean engine oil, do not allow engine oil to touch the coolant O-rings. 3. Install the pipe retaining plate and secure loosely, attach pipe retainer brackets and torque retaining plate bolts to 9 nm and reassemble intake pipes and hoses. 4. Fill the new coolant additive in the cooling system according to manufacturer guidelines. Observe the mixture ratio and filling-up procedure. 5. Only mix distilled water with coolant additives. Distilled water provides optimum corrosion protection. Page 4 of 9 © 2016 Audi of America, Inc. 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. 6. The filling procedure outlined in ElsaPro must be followed. It is important that the vacuum-down, filling and bleeding processes for the specific vehicle being repaired are used. 7. New software in the Engine Control Module (J623) (address word 0001) addressed the condition. 8. Follow all instructions in TSB 2011732: 00 Software Version Management (SVM), operating instructions. 9. Update the Engine Control module (J623) (address word 0001) using the SVM action code as listed in the table below if necessary: Model Engine Old Software Part Number Old Software Version (or lower) New Software Part Number New SVM Code Software Input Version (or higher) S6/S6 MY13 4.0TFSI 4G0906014B 0008 4G0906014B 0009 01A225 S6/S6 MY13 CEUC 4G0906014 0011 4G0906014 0012 01A225 S6/S6 MY13 CEUC 4G0906014A 0007 4G0906014A 0008 01A225 S6/S6 MY14 4.0TFSI 4G0906014E 0008 4G0906014E 0006 01A225 S6/S6 MY15 4.0TFSI 4G0906014E 0008 4G0906014E 0006 01A225 S6/S6 MY16 4.0TFSI 4G0906014C 0005 4G0906014C 0006 01A225 S6/S6 MY16 4.0TFSI 4G0906014D 0001 4G0906014D 0002 01A225 RS 7 MY14 4.0TFSI 4G0906560A 0005 4G0906560A 0006 01A225 RS 7 MY14 4.0TFSI 4G0906560 0011 4G0906560 0012 01A225 RS 7 MY14 4.0TFSI 4G0906560B 0007 4G0906560B 0008 01A225 RS 7 MY15-16 4.0TFSI 4G0906560F 0002 4G0906560F 0003 01A225 RS 7 MY16 Performance 4.0TFSI 4G0906560G 0001 4G0906560G 0002 01A225 A8 4.0TFSI MY13-14 4.0TFSI 4H0906014 0007 4H0906014 0008 01A225 Page 5 of 9 © 2016 Audi of America, Inc. 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. A8 4.0TFSI MY13-14 4.0TFSI 4H0906014A 0005 4H0906014A 0006 01A225 A8 4.0TFSI MY13-14 4.0TFSI 4H0906014B 0004 4H0906014L 0005 01A225 A8 4.0TFSI MY13-14 4.0TFSI 4H0906014C 0004 4H0906014C 0005 01A225 A8 4.0TFSI MY13-14 4.0TFSI 4H0906014D 0004 4H0906014D 0005 01A225 A8 4.0TFSI MY13-14 4.0TFSI 4H0906014H 0005 4H0906014H 0006 01A225 A8 4.0TFSI MY13-14 4.0TFSI 4H0906014L 0004 4H0906014L 0005 01A225 A8 4.0TFSI MY15 4.0TFSI 4H0906014G 0007 4H0906014G 0008 01A225 A8 4.0TFSI MY15 4.0TFSI 4H0906014J 0005 4H0906014J 0006 01A225 A8 4.0TFSI MY15 4.0TFSI 4H0906014K 0004 4H0906014K 0005 01A225 A8 Sport MY16 4.0TFSI 4H0906014N 0001 4H0906014N 0002 01A225 S8 MY13 4.0TFSI 4H0907557B 0004 4H0907557E 0004 01A225 S8 MY14 4.0TFSI 4H0907557E 0003 4H0907557E 0004 01A225 S8 MY15-16 4.0TFSI 4H0907557C 0005 4H0907557C 0006 01A225 S8 MY15-16 4.0TFSI 4H0907557D 0005 4H0907557D 0006 01A225 S8 Plus MY16 4.0TFSI 4H0907557G 0003 4H0907557G 0004 01A225 S8 Plus MY16 4.0TFSI 4H0907557H 0001 4H0907557H 0002 01A225 10. Check the software version number of the engine control unit: Page 6 of 9 © 2016 Audi of America, Inc. 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. Software version included in table: update the engine control unit with SVM code 01A225. Software version not included in table: already optimized or not available, only replace the O-rings. Warranty Claim Type: 110 up to 48 Months/50,000 Miles. G10 for CPO Covered Vehicles – Verify Owner. If vehicle is outside any warranty, this Technical Service Bulletin is informational only. Service Number: 1961 Damage Code: 0050 Labor Operations: Coolant pipes O-rings and oil feed pipe O-rings (Includes drain and fill cooling system.) 1961 5299 140 TU Check software level in ECM only (with no update needed) 2470 0199 Max 10 TU Check software level in ECM and perform update 2470 2599 Max 50 TU GFF No allowance 0 TU Road test prior to service procedure No allowance 0 TU Road test after service procedure 0121 0004 10 TU Diagnostic Time: 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 #2036167/5 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. Page 7 of 9 © 2016 Audi of America, Inc. 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. Required Parts and Tools Part Number Part Description Quantity N 91056801 Upper oil feed pipe O-ring 12 x 2 mm 2 WHT006335A O-ring coolant supply and return 2.0 mm (blue) order depending on lines installed on vehicle. 4 WHT006537 O-ring coolant supply and return 2.8 mm (black) order depending on lines installed on vehicle. 4 WHT005529 Intake pipe O-rings 2 G 013A8J1G Coolant additive 1 Outside material Distilled water (obtain locally) As needed (Max $10.00) Tool Number Tool Description 3371 Gauge – Gap Adjustment Tool V.A.G 1274/8 Adapter V.A.G 1274/10 Adapter VAS 6096 Cooling system charge unit T10007 A Refractometer Approved Battery Charger Additional Information The following Technical Service Bulletin will be necessary to complete this procedure: TSB 2011732 00 Software Version Management (SVM), operating instructions. All parts and service references provided in this TSB (2036167) are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information. Page 8 of 9 © 2016 Audi of America, Inc. 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. ©2016 Audi of America, Inc. 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. Page 9 of 9 © 2016 Audi of America, Inc. 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.