A231741 2040752-

23 MIL on, no start or rough running (DTCs P0087, P0088, P0191)
23 17 41 2040752/7 April 18, 2017. Supersedes Technical Service Bulletin Group 23 number 17-39 dated
February 13, 2017 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A3
2010 - 2012
All
TDI clean diesel
Q7
2009 - 2012
All
TDI clean diesel
Condition
REVISION HISTORY
Revision
Date
Purpose
7
-
Revised Service (Updated fuel sample analysis procedure)
Revised Required Parts and Tools (Updated part numbers)
6
02/13/2017
Revised Service (Added information on fuel sampling and analysis)
Revised Required Parts and Tools (Updated part numbers)
5
11/20/2015
Revised Service (Completely revised step 5 under High pressure fuel
pump replacement and fuel system repair)
Revised Warranty (Added labor operation 2050 1901 under Q7)
Revised Required Parts and Tools (Added Fuel delivery unit and fuel
gauge sender under A3; added suction pump and updated quantity of
seal rings under Q7)
 MIL on.
 Vehicle either runs roughly or does not start.
One or more of the following DTCs is stored in the engine control module (ECM), J623 (address word 0001):
 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)
Page 1 of 12
© 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.
Technical Background
Metallic particles in the high pressure fuel pump may cause the condition.
Production Solution
Not applicable.
Service
Note:
Before proceeding, perform all GFF diagnostic procedures and check all components to determine a root cause of
the condition, including testing supply pressure to the high pressure fuel pump (low pressure side) and checking
for internal leakage from the injectors and N276 pressure regulating valve.
If no root cause can be found, use the following procedure to check for metallic particles in the high pressure fuel
pump.
Initial diagnosis of high pressure fuel pump:
1. Prepare to remove the N290 fuel metering valve
by first cleaning the area around the valve then
drying the area using compressed air (Figure 1).
All debris must be removed from the area to
ensure that no debris enters the fuel system and
causes damage.
More information is available in the Elsa Repair
Manual at Engine >> Fuel Supply System >>
General Repair Information >> Clean Working
Conditions.
Figure 1. Area surrounding N290 fuel metering
valve.
Page 2 of 12
© 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. Remove the N290 fuel metering valve, and inspect
both the valve and valve bore for metallic particles
(Figure 2).
Figure 2. N290 fuel metering valve and valve
bore shown with and without metallic particles.
3. If metallic particles are found:
 This bulletin applies.
 The high pressure fuel pump and major
components of the fuel system will need to be
replaced. Proceed to the next section for
instructions.
If metallic particles are not found:
 This bulletin does not apply.
 Reinstall the N290 fuel metering valve using
light pressure. Before reinstalling, ensure that
the valve is free of contaminates.
 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).
Figure 3. N290 fuel metering valve O-rings.
Note:
Before reinstalling the N290 fuel metering valve,
check the O-rings for damage (Figure 3). If any
damage is found, the high fuel pressure pump
must be replaced outside of this bulletin.
Page 3 of 12
© 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.
To prevent damage to the O-rings during
reinstallation of the valve, lubricate the O-rings
with diesel fuel.
Fuel sampling and analysis:
Note:
A fuel sample must be taken and analyzed using the VAS 6774 tool before performing further repairs to
the vehicle.
Please review the instructional DVD included in the tool case titled ‘Fuel-Identification Kit VAS 6774’.
Here you will find a user manual, an FAQ, and a video that will describe the proper way to use, clean,
and maintain this tool. The instructions are also posted to ServiceNet by going to ServiceNet >>
Workshop Equipment >> Tool Information >> Instruction Manuals & Videos >> Manuals >> VAS 6774
Fuel Identification Unit Operating Instructions.
Note:
It is important that the specific gravity of the fuel sample be tested first before proceeding with sensor
head testing. Fuels with a specific gravity of 6.5 or lower cannot be tested using the VAS 6774 under any
circumstances. For this reason please disregard the order of testing as seen in the video and follow the
order in the manual that came with the tool.
1. Obtain a 500 mL fuel sample from the vehicle.
Page 4 of 12
© 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. Following the instructions included with
the VAS 6774 kit, test the specific
gravity of the fuel sample. A correct
specific gravity measurement is any
reading between 9 and 13 (Figure 4). If
the specific gravity reading falls outside
of those numbers proceed to section C,
Warranty Coverage Does Not Apply.
If the specific gravity is between 9 and
13 proceed to step 3.
Figure 4. Gravity measurement.
If the specific gravity test results in a reading between 9 and 13 a sensor head test is required to check
for gasoline particles.
Note:
If the specific gravity test results in a “Fail”, Warranty Coverage Does Not Apply.
Fuel samples which have a specific density between 0 and 6.5 indicate a fuel mixture which might be
flammable under certain conditions. If the specific gravity of the fuel sample is 6.5 or lower DO NOT use
the VAS 6774/7 to perform a sensor head test, Warranty Coverage Does Not Apply.
3. A sensor head test must be performed next to
check the fuel for gasoline residue. Follow the
instructions included with the tool to perform a
Page 5 of 12
© 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.
sensor head test. If the sensor head test results
in a “Pass” continue to step 3. If the sensor
head results in a “Fail”, Warranty Coverage
Does Not Apply.
Figure 5. Sensor head test results.
If the sensor head test results in a “Pass” and the specific gravity test results in a reading between 9
and 13 you may proceed with High Pressure Fuel Pump Replacement and Fuel System Repair.
High pressure fuel pump replacement and fuel system repair:
Before proceeding, check ElsaPro for the latest information and detailed instructions for removal and
replacement of the components listed in this TSB.
1.
Use suction pump VAS5226 to clean the fuel delivery unit and fuel tank.
2.
Fill the fuel tank with five liters of fresh diesel fuel.
3.
Use suction pump VAS5226 to completely drain the fuel tank.
4.
Replace the in-tank fuel pump.
5.
Replace the suction jet pump.
6.
Following the instructions in the Elsa repair manual, replace the following components:
 High pressure fuel pump (note that the supply and return line orientation for the HPFP may be
reversed on updated pumps installed on vehicles manufactured before 05/25/2010)
Page 6 of 12
© 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.
 High pressure fuel lines
 Fuel rail (with both sensors included)
 All fuel injectors
 Fuel return lines (overflow oil lines)
 Fuel filter
 Fuel filter housing
 Auxiliary fuel pump
7.
After replacements are complete, fuel the vehicle.
8.
Ensure that the fuel injector return line is properly seated and sealed.
9.
Using the VAS tester, perform the “Vent Fuel System” Guided Function. See the Elsa repair manual
at Engine>>Fuel Supply System>>20 Fuel Supply>>Fuel System, Bleeding for additional
information.
Tip: If the test plan is unavailable through Guided Functions, switch to Self Diagnosis >> Engine
Electronics >> Basic Settings >> 35, and perform the basic settings three times consecutively. For
UDS vehicles, perform basic settings for initial fueling.
10. Once the repairs are complete, test drive the vehicle.
11. Inspect for fuel seepage at the fuel injector return line connector. If seepage is found, the condition
must be corrected.
Warranty
Claim Type:
 110 – Verify Vehicle Warranty Coverage.
 G10 for CPO Covered Vehicles – Verify Owner.
 If vehicle is outside any warranty, this Technical Service Bulletin is
informational only.
Service Number:
2374
Damage Code:
0010
Labor Operations:
For Q7:
Page 7 of 12
© 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.
Fuel bleed
2003 0750
10 TU
Fuel tank cleaned
2010 2999
50 TU
Diesel fuel filter remove
+ reinstall
2034 1900
40 TU
Supply line cleaned
2038 2999
10 TU
Return line cleaned
2039 2999
10 TU
2 electric fuel pump
remove + reinstall
2066 2000
190 TU
Suction jet pump remove 2050 1901
+ reinstall
190 TU
2 distribution rail remove 2373 2047
+ reinstall
130 TU
6 injector remove +
reinstall
2340 2047
340 TU
High-pressure pump
remove + reinstall
2374 1947
220 TU
VAS 6774 Fuel analysis
0132 0000
20 TU
Fuel bleed
2003 0750
10 TU
Fuel tank cleaned
2010 2999
50 TU
Diesel fuel filter remove
+ reinstall
2034 1951
20 TU
Supply line cleaned
2038 2999
10 TU
Return line cleaned
2039 2999
10 TU
Electric fuel pump
remove + reinstall
2066 1900
110 TU
For A3:
Page 8 of 12
© 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.
Electric fuel pump (aux)
remove + reinstall
Diagnostic Time:
2066 1902
50 TU
Distribution rail remove + 2373 1912
reinstall
110 TU
4 injector remove +
reinstall
2340 2012
220 TU
Toothed belt remove +
reinstall
1524 1912
190 TU
High pressure pump
remove + reinstall
2374 1962
70 TU
VAS 6774 Fuel analysis
0132 0000
20 TU
GFF
0150 0000
Time stated on
diagnostic protocol
(Q7: Max 80 TU)
(A3: Max 70 TU)
Road test prior to service No allowance
procedure
0 TU
Road test after service
procedure
10 TU
0121 0004
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 #2040752/7
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 9 of 12
© 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.
Required Parts and Tools
For A3:
Part Number
Part Description
Quantity
03L130755A
High pressure fuel pump
1
03L130321
Fuel line
1
03L130089
Fuel rail (sensors)
1
03L130277A
Fuel injector
4
059130519
Seal ring (Fuel injector)
4
WHT000884
O-ring (Fuel injector)
4
03L130301
Pressure pipe
4
059130216C
Tensioning plate (Injector)
4
3C0127400C
Fuel filter/housing
1
1K0130307CE
Fuel line
1
03L201360G
Fuel line
1
1K0130295AQ
Fuel line
1
1K0130307BK
Fuel line
1
5N0130307CC
Fuel line
1
1K0919050AB
Fuel delivery unit and fuel gauge sender
1
5N0906129B
Auxiliary fuel pump
1
03L130301R
03L130301B
03L130301C
For Q7:
Page 10 of 12
© 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.
Part Number
Part Description
Quantity
059130755BT
High pressure fuel pump
1
059130300EC
Fuel line set
1
N 90770201
Spring clip
2
N 90926401
Spring clip
1
4B0422379
Spring clip
4
7L6201906A
Fuel hose (return)
1
7L6201905
Fuel hose (supply)
1
7L6130295AC
Fuel line (return)
1
7L6130295AT
Fuel hose (supply)
1
7L6130295BB
Fuel hose (return)
1
059130300DF
1 set of fuel lines
1
059130310AK
Fuel line
1
059130089AM
Fuel rail (left)
1
059130090AQ (MY09-10)
Fuel rail (right)
1
N 0138128
Seal ring (Fuel rail/fuel line)
2
059130131H (MY09-10)
Fuel line/hose
1
059130309AT
Fuel line
1
059130277AM
Fuel injector
6
WHT000884
O-ring (injector)
6
059130241CD
Pressure pipe
6
059130090BR (MY11-12)
059130218AF (MY11-12)
Page 11 of 12
© 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.
059130216C
Tensioning plate (Injector)
6
059130312K
Fuel line
1
7L6127401H (MY09-10)
Fuel filter
1
059103113G
Sealing cap (Cylinder head cover)
6
7L6919088F (MY09-10)
Fuel supply module
1
Suction pump
1
8E0919133B
Seal ring (Fuel supply module)
2
7L6203491D
Fuel radiator
1
1K0906089C (MY09-10)
Auxiliary fuel pump
1
8T0127401A (MY11-12)
7P6919088B (MY11-12)
4L0919715B (see ETKA)
4L0919715C (see ETKA)
4L0919715D (see ETKA)
Additional Information
All parts and service references provided in this TSB (2040752) 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 12 of 12
© 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.