ATU_Body_January

Body ATU
January 2018
Work specific to Cabriolet, A5/B9 Cabriolet
Audi of America
Winter 2017- 2018
Contents
01.
Malfunction of
convertible roof
compartment lid
(CRCL)
02.
Convertible roof
compartment tray
loose:
03.
Malfunction in
convertible roof
compartment lock:
1.1 Visible imprint on CRCL trim
2.1 Roof compartment tray
disconnected at drive
1.2 Convertible roof does not open
 malfunction of CRCL lock
2.2 Rear lid only opens
approximately 25 cm
3.1 Convertible roof receiver in
rear window frame – wiring
damaged
1.3 Hydraulic cylinder (CRCL
closed) fallen off CRCL
2.3 Rear lid is not pulled
completely closed
2.4 Rear lid does not open all the
way
04.
Manual operation of
convertible roof
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.1) Visible imprint on CRCL trim
Concern: Imprint on CRCL trim.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.1) Visible imprint on CRCL trim
Cause:
› Eyelet of cable guide can move freely and may, in the worst case,
become positioned against fixed stop pin.
› As a result, there is insufficient distance between edge of eyelet
and surface of CRCL trim.
› In this position, edge of eyelet makes an indentation (imprint) in
CRCL trim.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid
(CRCL)
1.1) Visible imprint on CRCL trim
Production modification:
› Eyelet of cable guide secured in place.
› This prevents eyelet from moving (stop pin no longer fitted)
and ensures adequate distance to CRCL trim.
› Gradual introduction starting week 20/2017
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.1) Visible imprint on CRCL trim
After sales service modification:
› Sanding/filing off top edge of eyelet, approximately 2mm.
› Check both sides (L/R) and adjust as necessary.
› Damaged CRCL trim can be replaced: Part No.: 8W7 867 877 B
Approximately
2mm
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.2) Convertible roof does not open  malfunction of CRCL lock:
Concern: convertible roof malfunction
› Roof does not open/close.
Data logger identifies one or more of the following
switches as the cause:
› F293
And/or
› F417
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.2) Convertible roof does not open  malfunction of CRCL lock:
Cause:
CRCL lock is constructed as a complete
assembly. Switches fitted in module show
delayed or different switching times when
closing CRCL.
The operation of convertible roof may be
interrupted as a result.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.2) Convertible roof does not open  malfunction of CRCL lock:
Production modification:
› Optimized construction of switch contacts in CRCL lock assembly implemented (CW
19/2017) data showing > 04s.
› Carried out for vehicles already produced.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.2) Convertible roof does not open  malfunction of CRCL lock:
After sales service modification:
› Check convertible roof system (GFF/MVB) for plausibility.
› In relevant cases, replace CRCL lock assembly with Part No.: 8W7 825 823 A.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.3) Hydraulic cylinder (CRCL closed) fallen off CRCL:
›
Still possible to open/close convertible roof.
Other possible scenarios:
›
Fallen off: lying detached on blocked roof hinge flap with no further damage.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.3) Hydraulic cylinder (CRCL closed) fallen off CRCL:
›
Opening/closing interrupted.
Other possible scenarios:
›
›
Fallen off: push rod of hydraulic cylinder bent.
Subsequent damage: roof frame trim and/or convertible roof cover/headliner is damaged.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.3) Hydraulic cylinder (CRCL closed) fallen off CRCL:
Cause:
› Ball socket of corresponding hydraulic cylinder on CRCL becomes
detached when roof is closed.
› If the roof is operated, piston rod can collide with and damage
various surrounding components.
Background information:
Due to concerns of creaking noises when CRCL is open,
tolerances at ball stud and ball socket were reduced:
› Paint applied to ball stud
› Plastic ring for ball socket
As a result, the retaining clip of ball socket does not reach
end position on ball stud and can become unfastened due to
relative movement.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.3) Hydraulic cylinder (CRCL closed) fallen off CRCL:
Production modification:
› Unpainted ball studs with optimized inserts in ball sockets to ensure largest possible coverage
of retaining clip.
Audi of America Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
1) Malfunction of convertible roof compartment lid (CRCL)
1.3) Hydraulic cylinder (CRCL closed) fallen off CRCL:
After sales service modification:
› Exchange the hydraulic cylinder.
Important:
› As specified in ETKA, ball studs must be replaced as well, Part No.:
WHT-007-864 (6x)
›
Ball studs are replaced on both sides on vehicles manufactured
prior to implementation VIN.
›
Prevention
Important:
› Retaining clip must be pressed in flush on ball socket.
Note:
Affected and damaged components must be serviced as appropriate.
OK
Not OK
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
2) Convertible roof compartment tray loose:
2.1) Roof compartment tray disconnected at drive:
›
No cases have occurred where this affects roof
opening/closing.
Concern:
› Upon opening luggage compartment lid, the customer sees
that front trim of variable roof compartment tray is
detached on left side.
› Tray can no longer be operated using button or convertible
roof control system.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
2) Convertible roof compartment tray loose:
2.1) Roof compartment tray disconnected at
drive:
›
No cases have occurred where this affects roof
opening/closing.
Cause:
› Retaining ring of drive shaft is not properly engaged
during assembly.
› When roof compartment tray is operated or
pressure is applied to front trim (e.g. loading
luggage compartment), the retaining ring may come
loose and fall off.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
2) Convertible roof compartment tray loose:
2.1) Roof compartment tray disconnected at drive:
›
No cases have occurred where this affects roof
opening/closing.
not OK
Production modification:
› Optimized assembly process.
After sales service modification:
›
›
Press in the retaining clip correctly so that it is flush.
Check according to assembly process (A) and
subsequently check function Part No.: 8W7 898 863
(clip in repair kit).
To verify the repair, the roof compartment tray can
be operated via switch E896.
OK
A
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
3) Malfunction in convertible roof compartment
lock:
3.1) Convertible roof receiver in rear window
frame – wiring damaged:
›
Convertible roof cannot be opened/closed.
Concern: convertible roof malfunction
› Roof does not open/close.
Data logger identifies the following switch as the
cause:
› F294
Additional data code stored in data logger:
› Short to earth (poss. sporadic)
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
3) Malfunction in convertible roof compartment
lock:
3.1) Convertible roof receiver in rear window
frame – wiring damaged:
›
Convertible roof cannot be opened/closed.
Cause:
› Insulation on internal wiring for convertible roof
receiver damaged at supplier when two halves of
assembly housing are joined. Over time, this leads to a
short to earth/short circuit caused by relative
movement.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
3) Malfunction in convertible roof compartment lock:
3.1) Convertible roof receiver in rear window frame – wiring damaged:
›
Convertible roof cannot be opened/closed.
Production modification:
› Affixed the wiring to main body with Cyberbond 2241 during attachment of assembly parts.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
3) Malfunction in convertible roof compartment lock:
3.1) Convertible roof receiver in rear window frame – wiring damaged:
›
Convertible roof cannot be opened/closed.
After sales service modification:
› Installation of new part, carried out for vehicles already produced.
Audi of America
Winter 2017- 2018
Work specific to Cabriolet
A5/B9 Cabriolet
4) Manual operation of convertible roof
For operation of convertible roof by customer:
›
›
There is no option to the open roof through manual operation.
Manual operation to close the roof is described for customers in the Owner’s Manual.
For service/workshops:
It is only necessary to open the convertible roof manually if this is part of analysis or repairs in
the workshop. The tensioner can be raised to open the CRCL for further analysis as noted
below.
Raising tensioner when convertible roof is closed and implausible switch position indicated:
›
When the convertible roof is closed and an implausible switch position is preventing normal roof
operation, the tensioner can be raised by holding the convertible roof button in “open” direction
for >10 sec.
Conditions:
Terminal 15 on
Speed: 0 km/h
Actuation time: 2 sec.
›
Luggage compartment can be opened via hard key.
Q7/A4 – power-operated rear lid
Audi of America
Winter 2017- 2018
Contents
01.
Customer concern
02.
Known problems
(with measures)
03.
Analysis of causes
2.1 Rear lid lock sticks in first
catch
Eliminating functional problems
using measured values in rear lid
control module, J605 (address
word 006D)
2.2 Rear lid only opens
approximately 25 cm
2.3 Rear lid is not pulled
completely closed
2.4 Rear lid does not open all the
way
04.
Summary
Audi of America
Winter 2017- 2018
Customer concern
Initial analysis:
›
A wide variety of static and sporadic problems
related to how the power-operated rear lid
opens and closes.
Objective:
›
Identifying the cause and avoiding incorrect
replacement or repeat repairs.
Audi of America
Winter 2017- 2018
Customer concern
Model:
Area of fault: Power-operated rear lid
VIN: XXXXXXXXXXX
Description of fault:
Opening the rear lid:
›
›
Approximately 50% of the time, the rear lid only opens about 30 cm.
Does not matter what method of operation was used (key, button in rear lid or control in driver
door).
Quick solution
1) Repeat opening command twice:
›
Rear lid opens as far as programmed end position.
2) Alternatively: Press rear lid manually into lock, repeat opening command:
›
Lid opens easily as far as programmed end position.
Reprogramming the end position did not solve problem:
›
After slowly pushing the rear lid up manually into the end position and pressing the close button for
5 seconds, the lid can only be closed manually (close button does not work).
Audi of America
Winter 2017- 2018
Customer concern (continued)
Closing the rear lid
One-time event:
›
After pressing the close button, the lid only closes halfway.
Solution:
›
Close lid manually.
Rear lid opens unintentionally
One-time event:
›
Upon returning to the locked vehicle, the rear lid was found open.
Audi of America
Winter 2017- 2018
Rear lid lock sticks in first catch
Embedded video:
Audi of America
Winter 2017- 2018
Rear lid lock sticks in first catch
Problem reported by customer/results found by workshop:
When opened, the power-operated rear lid remains stuck in the first catch of the rear lid lock. It
can only be opened by pressing the button in the handle, on the remote control key or in the door
trim. The problem usually occurs when opening the rear lid for the first time.
Technical background:
Due to insufficient coverage at the lowest tolerance for the snow load lever, the locking pawl in the
lock is released too early.
›
When operated slowly, the lock sticks in the first catch (customer must unlock twice).
Production measure:
›
Modified component geometry of snow load lever.
Service procedure:
›
›
Replace rear lid lock.
There are no DTC(s) stored in the diagnostic memory.
Audi of America
Winter 2017- 2018
Rear lid only opens approximately 25 cm
Audi of America
Winter 2017- 2018
Rear lid only opens approximately 25 cm
Audi of America
Winter 2017- 2018
Rear lid only opens approximately 25 cm
Embedded video:
Audi of America
Winter 2017- 2018
Rear lid only opens approximately 25 cm
Problem reported by customer/results found by workshop:
During opening, the power-operated rear lid stops moving after opening approximately 25 cm
(sporadic fault). It is then generally only possible to completely open and close the rear lid by hand.
This problem often depends on the temperature.
Technical background:
Bent switch lugs on the first catch microswitch can prevent it from switching, causing the first
catch to remain closed although the rear lid lock is completely released.
›
The rear lid opens approximately 25 cm and then stops, as only from this opening height
onwards does the rear lid control module require a signal from the first catch to continue
powering the rear lid drives.
Production measure:
›
Modified packaging at sub-supplier and camera surveillance of switch lugs on production line
starting in October 2017 and onwards.
Audi of America
Winter 2017- 2018
Rear lid only opens approximately 25 cm
Service procedure:
If the problem is constant, the rear lid lock status can be read out from the measured values in the
rear lid control module, J605 (address word 006D).
›
›
›
›
Status of rear lid lock.
Rear lid lock in first catch.
Main catch open.
First catch closed.
As the problem often depends on the temperature, you can try to reproduce the problem by
warming or cooling the rear lid lock:
›
›
There are no DTC(s) stored in the diagnostic memory.
Replace rear lid lock.
Audi of America
Winter 2017- 2018
Rear lid is not pulled completely closed
Audi of America
Winter 2017- 2018
Rear lid is not pulled completely closed
Power latching
system drive
Bowden cable
Rear lid lock with power latching system
Audi of America
Winter 2017- 2018
Rear lid is not pulled completely closed
Problem reported by customer/results found by
workshop:
The power-operated rear lid does not close completely/closes
only as far as the first catch in the rear lid lock. The rear lid must
be pressed fully closed by hand. The problem occurs most often
at cold ambient temperatures.
Technical background of first possible cause:
Too great a tolerance in the screw shaft drive can cause the
power latching system drive to stick. The power latching system
drive does not reach the end position after it is operated. End
switch for power latching system drive is not operated.
›
The rear lid control module creates the DTC B113E29 “Power
latch - implausible signal - static” in the diagnostic memory.
›
The rear lid control module cuts off current to the power
latching system drive until this DTC is at least passive/sporadic
again.
Production measure:
›
Additional component check at -4° F screw shaft sorting
starting in December 2016 onwards.
Audi of America
Winter 2017- 2018
Rear lid is not pulled completely closed
Service procedure:
DTC is generally present in diagnostic memory:
›
If problem is constant, the DTC B113E29 (Power latch – implausible signal – static) can be read
out of the diagnostic memory of the rear lid control module, J605 (address word 006D).
›
As the problem often depends on the temperature and only occurs after closing the rear lid a
second time (after a longer period when the rear lid was not operated), the DTC B113E29
(Power latch - implausible signal - passive/sporadic) may be stored in the diagnostic memory, or
may have already been erased by the reset counter/driving cycle.
›
Replace power latching system drive.
Audi of America
Winter 2017- 2018
Rear lid is not pulled completely closed
NNN
NN
Audi of America
Winter 2017- 2018
Rear lid is not pulled completely closed
Technical background of second possible cause:
A bent switch lug on the main catch microswitch can cause the microswitch to switch prematurely
even though the rear lid lock is only closed as far as the first catch.
›
›
The rear lid control module registers that both microswitches already indicate a closed position.
The rear lid control module does not send current to the power latching system motor, as the
control module registers from the microswitch signals that the rear lid lock is already closed
(even though the rear lid lock is physically only in the first catch).
Production measure:
›
Modified packaging at sub-supplier and camera surveillance of switch lugs on production line
starting in October 2017 onwards.
Service procedure:
›
›
Replace rear lid lock.
There are no DTC(s) stored in the diagnostic memory.
Audi of America
Winter 2017- 2018
Rear lid is not pulled completely closed
Service procedure:
If the problem occurs, the rear lid lock status can be read out from the measured values in the rear
lid control module, J605 (address word 006D).
›
›
›
›
Status of rear lid lock.
Rear lid lock closed.
Main catch closed.
First catch closed.
As the problem often depends on the temperature, you can try to reproduce the problem by
warming or cooling the rear lid lock:
›
›
There are no DTC(s) stored in the diagnostic memory.
Replace rear lid lock.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Without pressing
With pressing
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Problem reported by customer/results found by workshop:
›
›
The power-operated rear lid does not open all the way. After opening, there is still
enough play towards top that it can be pressed by hand for the last 6 to 10 cm of the
possible opening height.
The problem generally occurs at cold ambient temperatures.
Technical background:
›
›
When vehicles leave the factory, the rear lid has a small amount of play when it is
completely open. The play increases if the opening height has been reprogrammed
via the button in the rear lid trim.
This is caused by play in the drive system and the value for the upper lock-in range
that was entered at the factory. The result is that the maximum power-operated
opening range can no longer be set.
Production measure:
›
No action planned at this time.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Service procedure:
›
The instructions below describe the procedure for permanently setting the rear lid to open to the
maximum power-operated position after reprogramming.
First, perform a basic setting for the rear lid control module, J605 (address word 006D).
›
Please carry out all steps as described in the test program in the rear lid control module, J605
(address word 006D) under “Basic setting - adapt opening angle of tailgate”.
›
›
Then change the value for the upper lock-in range to 150, as described on the following slides.
Changing this value ensures that, after reprogramming, the rear lid opens to the maximum
power-operated position when it is programmed to open all the way.
Note:
After this measure is carried out, the maximum power-operated position is only set after the rear
lid is opened 2 or 3 times.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Adjusting upper lock-in range
1) In self-diagnosis, select control module 006D rear lid electronics
From the self-diagnosis functions, select the “Adaptation” tab.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Adjusting upper lock-in range
2) Under “Adaptation/Parameters” select “Upper lock-in range”.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Adjusting upper lock-in range
3) You can then see that “Current value, 100” is the factory’s set value.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Adjusting upper lock-in range
4) Enter 150 for the value under “Entry” then press the “Apply” button.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Adjusting upper lock-in range
5) Confirm that you really want to apply the change by selecting “Yes”.
Audi of America
Winter 2017- 2018
Rear lid does not open all the way
Adjusting upper lock-in range
6) The change has now been made successfully if 150 is entered as the “Current value”.
Audi of America
Winter 2017- 2018
Eliminating functional problems using measured values
in rear lid control module, J605 (address word 006D)
›
›
Functional problems are often not shown by a DTC in the diagnostic memory.
›
Checking and evaluating the signals via the measured values provides a targeted method of
identifying the components causing the issue.
›
See embedded pdf below:
Due to a lack of redundancy, the control modules may not check the plausibility of the
microswitch settings for the rear lid lock.
Audi of America
Winter 2017- 2018
Q7/A4 – power-operated rear lid
Summary
›
Functional problems with the power-operated rear lid are often not detected by DTC(s) in the
diagnostic memory.
›
›
An exact description of the problem is essential, especially for sporadic issues.
Faults in the functions can be identified using the measured values.
Noises from front seats
Audi of America
Winter 2017- 2018
Agenda
01.
02.
03.
TT (3rd generation): Noises from
front seats
MLB: Noises from seat depth
adjuster
MLB: Noises from seat rake
adjuster
Audi of America
Winter 2017- 2018
TT (3rd generation): Noises from front seats
›
If there are noises coming from the seat structure and/or backrest structure of the front seats on
the TT (3rd generation), please check the points described in the following instructions before
replacing the relevant structure.
›
If the instructions described on the following charts do not eliminate the problem, the affected
seat frame/lumbar support can be exchanged for a new component.
›
Please document the issue clearly using suitable photographs/videos.
Audi of America
Winter 2017- 2018
TT (3rd generation): Noises from front seats – e.g. lumbar
support
If the noises are coming from the area of the outer backrest
frame, this may be caused by the connection between the lumbar
support and the outer backrest frame.
Cause:
›
Play between rivet for lumbar support and lower outer backrest frame.
Solution:
›
Drill out old rivet and fit a larger rivet.
Audi of America
Winter 2017- 2018
TT (3rd generation): Noises from front seats – e.g. seat
frame
If the noises are coming from the area of the seat frame, this may
also be caused by the connection to the hinged lever (top).
Cause:
›
Play between connection for hinged lever (top)
and seat pan.
Solution:
›
Please try to eliminate the noise by varying the
height of the seat.
›
If this is not successful, the seat frame can be
replaced.
Audi of America
Winter 2017- 2018
MLB: Noises from seat depth adjuster
›
If there are noises coming from the seat structure of the front seats (sports seats) on the B9
(A4/A5), Q7 (successor), Q5 (successor), or TT (3rd generation), please check the following
points in addition to the familiar topics.
›
If the instructions described on the following charts do not eliminate the problem, the affected
seat frame/seat depth adjustment unit can be exchanged for a new component.
›
Please document the issue clearly using suitable photographs/videos.
Audi of America
Winter 2017- 2018
MLB: Noises from seat depth adjuster
If the noises are coming from the area of the seat depth adjuster, this may also be
caused by the connection between the seat depth adjustment unit and the seat
frame.
Cause:
›
Play between bolted connection for seat depth
adjustment unit and seat frame.
Solution:
›
Fit self-locking nuts instead of nuts and increase
tightening torque to 7 Nm.
Audi of America
Winter 2017- 2018
MLB: Noises from seat rake adjuster
If the noises are coming from the area of the seat frame, this may also be caused by the
seat rake adjuster at the transverse tube of the seat frame.
Cause:
›
Play in the seat rake adjuster shaft.
Solution:
›
›
Please try to eliminate the noise by varying the seat rake adjustment.
If this is not successful then the seat frame can be replaced.
Audi of America
Winter 2017- 2018
Noises from front seats
Summary
›
›
In addition to the noise-related topics with which you are already familiar (various TSBs in
circulation), please also check the following areas depending on the source of the noise:
›
›
›
›
Lumbar support mounting.
Seat height adjustment unit.
Seat depth adjuster.
Seat rake adjuster.
General rule: Repair is preferable to replacement!
Thank you!