A011496 2018260-

Technical Service Bulletin
01 MIL on (P1545, P0121, P0123, P0221 or P0222 stored in ECM)
01 14 96 2018260/8 September 26, 2014. Supersedes Technical Service Bulletin Group 01 number 13-76 dated
March 14, 2013 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A6
2005-2008
All
3.2 FSI
A4
2005-2008
All
2.0 and 3.2 FSI
A4 Cabriolet
2007-2008
All
2.0
TT
2008
All
2.0
A3
2006-2009
All
2.0
Q7
2007-2009
All
3.6
Condition
REVISION HISTORY
Revision
Date
Purpose
8
-
Revised Required Parts and Tools (Updated part quantity)
7
3/14/2013
Revised Required Parts and Tools (Updated parts)
6
2/22/2013
Revised Required Parts and Tools (Updated parts)
5
6/4/2010
Revised header data (Controlling TSB display in ElsaWeb)
4
12/1/2008
Revised header data to add model
Revised Title
3
11/20/2008
Revised Title to include Repair Group
• MIL on.
• A number of incident memory entries with regard to the throttle valve are stored in the engine control module
(ECM), J623 (01). In most cases, the entries are sporadic.
The most frequent incident memory entries are:
• DTC P1545 (throttle control malfunction)
• DTC P0121 (throttle potentiometer – G69 implausible signal)
• DTC P0123 (throttle potentiometer – G69 signal too big)
• DTC P0221 (angle transmitter 2 for throttle actuator G188 implausible signal)
© 2014 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
• DTC P0222 (angle transmitter 2 for throttle actuator G188 signal too small)
Technical Background
Contact resistance in the ECM wiring – throttle valve.
Production Solution
Optimized wiring and contacts.
Service
Wiring Harness and Connector Repairs, General Information
• Observe general notes for repairs on the vehicle electrical system chapter of the repair manual. See Repair
Manual >> Electrical System >> Electrical Equipment General Information >> Wiring 97.
• For repairs on vehicle electrical system, soldering is not permitted.
• Do not repair crimp connectors. If necessary, lay a wire parallel to the inoperative wire.
• After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
• Yellow wires are to be used exclusively for wiring harness repairs.
• Mark repaired areas using yellow adhesive tape.
• Yellow wires and areas in the wiring harness wrapped with yellow adhesive tape mark a previously performed
repair.
• Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into
basic setting.
Procedure
1.
With the ignition switched off, disconnect battery ground (GND) cable. See Repair Manual >> Electrical
Equipment >> Repair Group 27 >> Battery. Disconnecting battery ground wire is necessary to work safely on
the vehicle electrical system.
Warning:
The above step must be completed to ensure safety during the repair. Also, observe all country-specific
regulations.
2.
Use the applicable repair manual in Elsa in addition to the description below. Check ETKA to determine if set
1 or set 2 is needed.
For terminal 3 and 5, use 1.0qmm wire. For all other 0.5qmm.
© 2014 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
3.
Lengthen wires and preassemble
seals as shown (Figure 1).
Figure 1. Correctly preassembled wires and seals.
4.
On the new housing, remove pink
lock with small flathead screwdriver,
using the slot on the pink lock (Figure
2).
Figure 2. The slot to be used to remove the pink lock.
5.
Insert all terminals into housing until they audibly click.
6.
Reinstall pink lock.
7.
Using the appropriate assembly tool,
slide the single wire seal up the repair
wire until it contacts the housing.
Continue to slide the single wire seal
into the housing as far as the stop
(Figure 3).
Figure 3. The single wire seal, slid as far as the stop.
© 2014 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
8.
Strip wires 6-7mm using tool VAS
1978/3. Install crimp connectors using
crimping pliers (base tool) -VAS
1978/1-2 with the head VAS 1978/1-1
(Figure 4).
Figure 4. Crimp connectors installed on wire ends.
9.
Remove car harness insulation to the appropriate length (approximately 24cm).
10. Lay new harness beside the old harness. Cut original wires to fit the new harness.
11. Twist wires 3 and 5, and 1, 2, 4, and 6 as they were originally.
12. Crimp connections.
13. Use shrink tip for hot air gun (VAS 1978/15) with hot air gun 220 V/ 50 Hz (VAS 1978/14) to shrink the shrink
tubes.
Note:
When heat-shrinking crimp connections, be careful not to damage any other wiring, plastic parts or insulating
material with the hot nozzle of the hot air gun.
Always observe operating instructions of heat gun.
14. Re-insulate harness with yellow tape.
15. Check proper function. If necessary, check DTC memory, erase and/or bring systems into basic setting.
Note:
The main throttle is allowed to be replaced only if faults reoccur after the repair.
© 2014 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:
9713
Damage Code:
0040
Labor Operations:
Repair wire harness for engine
9752 4199
110 TU
Diagnostic Time:
GFF
No allowance
0 TU
Road test prior to service procedure
No allowance
0 TU
Road test after service procedure
0121 0004
10 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 #2018260/8
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
Quantity
Quantity
2.0L
3.2L
3.6L
4H0973713
Housing (set 1)
1
1
000979025FA
Wires set 0.5qmm
1
1
000979150EA
Wire set 1.0qmm
1
1
1J0973713
Housing (set 2)
1
0
1
000979038FA
Wires set 0.5qmm
2
0
2
000979131EA
Wire set 1.0qmm
1
0
1
000979940
Connectors with shrink tube (used with either set)
6
6
6
4B0972740
Wire seals (used with either set)
6
6
6
NOTE: Please verify correct housing and associated wire set in ETKA with specific VIN.
© 2014 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
Tool Number
Tool Description
VAS 1978/3
Strip pliers
VAS 1978/1-2
Crimp pliers
VAS 1978/1-1
VAS 1978/15
Hot air gun
Additional Information
All parts and service references provided in this TSB (2018260) are subject to change and/or removal. Always
check with your Parts Department and service manuals for the latest information.
© 2014 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.