A011710 2035002-

01 MIL on (DTC P0491/P0492 Secondary Air Injection System Bank 1/2 Insufficient Flow)
01 17 10 2035002/5 April 20, 2017. Supersedes Technical Service Bulletin Group 01 number 16-55 dated March
14, 2016 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A8
2010 - 2012
All
4.2FSI
Condition
REVISION HISTORY
Revision
Date
Purpose
5
-
Revised Required Parts and Tools (Updated part number)
Revised Service (Completely revised)
4
03/15/2017
Revised Required Parts and Tools (Updated part number)
3
10/22/2015
Revised Production Solution (Added solution)
Revised Service (Completely revised)
Revised Warranty (Updated TU for GFF)
Updated Required Parts and Tools (Removed parts; updated part
numbers)
 MIL on.
The following DTCs are stored in the engine control module (ECM), J623 (address word 0001):
 DTC P049100 (secondary air system bank 1, low flow)
 DTC P049200 (secondary air system bank 2, low flow)
Technical Background
The DTCs may appear during monitoring of the secondary air system during the engine cold starting phase. With
the electric solenoid valves controlled, a diagnosis cycle is performed and the secondary air pressure is measured
for a specified value.
The air pressure can be influenced by several factors within the secondary air system or the vacuum system.
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© 2017 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.
Production Solution
Improved combination valves.
Service
Check the vacuum system for leaks
During the catalyst heating phase, the secondary air valves could close too early if vacuum supply is low.
Low vacuum supply can be a result of a leak in the vacuum system, so it is necessary to check the entire
system for leaks.
1. Check the vacuum check valve for leaks (Figure
1). The direction of flow should only be towards
the intake manifold.
If a leak is found at the check valve, replace the
valve and recheck.
Figure 1. Vacuum check valve.
Page 2 of 6
© 2017 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.
2. With the hose to the check valve disconnected,
apply 400 mmHG of vacuum with the VAS 6213
hand vacuum pump (Figure 2).
If the vacuum supply drops during the first 10
minutes of the test, check the complete vacuum
system and solenoid changeover valves for
leaks using the diagram below.
See diagram (Figure 3):
A: Cylinder Bank 1 Intake Manifold Flap Vacuum
Actuator
B: Cylinder Bank 2 Intake Manifold Flap Vacuum
Actuator
C: Intake Manifold Runner Control Valve N316
Figure 2. VAS 6213 hand vacuum pump.
D: Left Secondary Air Injection (AIR)
Combination Valve
E: Right Secondary Air Injection (AIR)
Combination Valve
F: Cylinder Head Coolant Valve N489 – Vacuum
Actuator
G: Secondary Air Injection Solenoid Valves N112
and N320
1: Vacuum from intake manifold
2: Vacuum reservoir of cylinder head (0.9 l)
3: Vacuum reservoir in inner valley of engine 0.7
l)
Figure 3. Vacuum Diagram
Repair as necessary.
4. If the engine warning light has come on in combination with DTC P049100 and/or DTC P049200,
proceed as follows after the vacuum system was checked and with the procedure listed above.
5. Replace the following components:
 Bank 1 and Bank 2 - Combination valves and gaskets (079 131 101 AN and 06A 131 120 D)
Page 3 of 6
© 2017 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.
 Secondary air injection sensor 1 (G-609) (06K 906 052). SAI solenoid valves N112 and N320 for
combination valves (037 906 283 C)
 Delete the DTC entry before setting the readiness code.
If the DTC is not logged after two engine starts, return the vehicle to the customer.
Check the exhaust catalyst
Only perform this section if the vehicle has a history of prior misfire or catalyst efficiency DTC.
Vehicles with misfire DTCs (e.g., P0300, P0301 – P0308, or P130A) or faulty catalyst DTCs (e.g.,
P042100 or P043100) in current or older diagnosis protocols may have faulty exhaust catalysts.
1.
Remove pre and post oxygen sensors and endoscope the catalysts from both ends and assess the
honeycomb structure for damage.
2.
If damage is found, repair as necessary.
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:
2640
Damage Code:
0010
Labor Operations:
Combi valves remove + reinstall (both)
2640 2019
40 TU
Secondary Air Solenoid Valves N112/N320 remove +
reinstall both
2644 1999
40 TU
Pressure sensor G609 remove + reinstall
2675 1919
20 TU
Front heated oxygen sensors remove + reinstall both
2469 2019
130 TU
Rear oxygen sensors remove + reinstall both
2473 2019
90 TU
Borescope check of both exhaust catalysts
2640 0299
30 TU max
Page 4 of 6
© 2017 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.
Diagnostic Time:
Vacuum system checks
2640 0299
30 TU max
GFF
0150 0000
Time stated on
diagnostic
protocol (50 TU
max)
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 #2035002/5
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.
Required Parts and Tools
Part Number
Part Description
Quantity
06K 906 052
Secondary air injection sensor (G609)
1
06A 131 120 D
Combination valves gaskets
2
079 131 101 AN
Combination valves for secondary air system
2
037 906 283 C
Solenoid valves N112/N320 for operating combination
valves
2
Tool Number
Tool Description
VAS 6213
Hand Vacuum Pump
3337
Ring Spanner 7 piece set for oxygen sensor removal (if required).
Page 5 of 6
© 2017 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.
Additional Information
All parts and service references provided in this TSB (2035002) are subject to change and/or removal. Always
check with your Parts Department and service manuals for the latest information.
©2017 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 6 of 6
© 2017 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.