ATU_Engine_Janua

Engine ATU
January 2018
Introduction of new coolant for A8 and R8 in 2017
Audi of America
Winter 2017- 2018
Introduction of new coolant for A8 and R8 in 2017
01.
Requirements which
modern coolant must
fulfill
04.
Summary
02.
G12evo as successor
to G13
03.
Handling G12evo
during servicing
Audi of America
Winter 2017- 2018
Requirements which modern coolant must fulfilll
Coolant make-up and tasks
Additives (~2%)
Alcohols (~38%)
Water (~60%)
Increase in
boiling point
and in frost
protection.
Corrosion
protection,
defoamer
components, and
stabilizers.
Protection
from
overheating.
IMPORTANT! Mixture ratio must be observed:
›
›
Not enough coolant concentrate  danger of freezing, corrosion, and boiling.
Too much coolant concentrate  danger of overheating.
Audi of America
Winter 2017- 2018
Requirements which modern coolant must fulfill
Rising complexity of cooling systems:
›
Increasing number of components in coolant circuit.
›
Increasing range of materials.
›
Thermal management with brief temperature fluctuations:
› Switchable coolant pump.
› Separate cooling for cylinder head/block.
› Map-controlled thermostat.
› Electric auxiliary coolant pumps.
› Start/stop system.
›
The next generation of coolant must fulfill all these requirements.
Audi of America
Winter 2017- 2018
G12evo as successor to G13
Use of G12evo in the A8 and R8:
WAUYGB4HXHN023176
›
›
WUAKBAFX0J7900292
Planned for use across the entire Audi fleet.
Testing and verification will be performed gradually and individually for each
engine/model.
G12evo must NOT be used for
other vehicle models and engines yet!!
Audi of America
Winter 2017- 2018
Handling G12evo during servicing
Can be
mixed
with…
blue/green
G11
1994
onwards
red
G12
Standard initial filling
1996
onwards
violet
G12+
2000
onwards
G11
G12
G12+
brown
G12++
brown
G13
brown
G12evo
brown
Can be mixed in any ratio
Can be mixed but reduces corrosion protection
Cannot be mixed
violet
violet
2005
onwards
2012
onwards
G12++
G13
violet
G12evo
2017
onwards
NOTE:
G12evo can only be
used for vehicles
with the
corresponding
approval (select
coolant by accessing
ETKA using chassis
number or model
selection).
Audi of America
Winter 2017- 2018
Handling G12evo during servicing
Hand-held refractometer T10007A is suitable for G12evo generation:
›
The G12++ scale must be used to read off the frost protection for G12evo.
›
For mixtures (e.g. with G13 added) the G13 scale should always be used.
Audi of America
Winter 2017- 2018
Handling G12evo during servicing
Corresponding information already incorporated in Owner's Manual:
The information can be found here:
Service and care >> Checking and topping up fluids >> Cooling system.
Audi of America
Winter 2017- 2018
Introduction of new coolant for A8 and R8 in 2017
Summary
›
Thermal management in engines requires a more robust coolant.
›
G12evo is (currently) approved for the A8 and R8 only.
›
G12evo is compatible with earlier generations of coolant:
›
To select coolant or check approval, access ETKA using chassis number or model
selection.
›
Gradual introduction for other vehicle models and engines.
›
Hand-held refractometer T10007A can still be used.
R8 (new model) – checking engine oil level
Audi of America
Winter 2017- 2018
Agenda
01.
Engine oil system of
R8 (new model)
02.
Determining oil level
using MMI
04.
Summary
05.
Backup
03.
Determining oil level
using oil gauge tester
Audi of America
Winter 2017- 2018
Engine oil system of R8 (new model)
Dry sump lubrication
Engine oil reservoir
Oil filter
Engine oil
cooler
Combined
oil/coolant pump
Engine oil cooler 2
with own coolant
thermostat regulation
Audi of America
Winter 2017- 2018
Determining oil level using MMI
The customer can only check the engine oil level via the MMI.
Opening and closing the engine lid resets the engine oil display.
Requirements for generating engine oil level:
›
›
›
›
›
Engine lid must be closed (or engine lid lock engaged).
Engine speed must be ensured: measurement between idling and 4500 rpm.
Engine oil temperature: between 140 and 248 °F.
Longitudinal and lateral acceleration: between +/- 0.2g.
This means: depending on the test conditions, the amount of time required for the oil level to be
shown on the MMI may vary.
Note:
The oil level is determined most quickly with the engine idling or when driving at a constant speed
on level roads.
Special considerations:
The engine oil system requires a minimum of approximately 9 quarts of oil to generate an oil level
reading and display this on the MMI.
Audi of America
Winter 2017- 2018
Determining oil level using oil gauge tester
Two different oil gauge testers are available:
›
›
Oil gauge tester T40178 with test adapter T40178A/1.
Adjustment
value
Min. oil level
Max. oil level
378
0
17
Oil gauge tester T40178A with test adapter T40178A/1.
Adjustment
value
Min. oil level
Max. oil level
191
0
17
Audi of America
Winter 2017- 2018
Determining oil level using oil gauge tester
Test requirements:
›
›
›
›
Vehicle must be level.
Engine oil temperature between 212 °F and 230 °F.
Allow engine to run at idling speed for approximately two minutes.
Wait approximately two minutes after switching off engine.
Special considerations:
For a correct reading on the oil gauge
tester, position the scale of the tester
in the opposite direction of vehicle
travel. Otherwise the measured value
may be smudged.
Audi of America
Winter 2017- 2018
R8 (new model) - engine oil level
Summary
›
Engine oil level can only be measured with engine lid closed.
›
Oil level display on MMI depends on a number of factors:
›
›
Depending on driving profile and operational status of engine, time required to generate oil
level display may vary.
›
Engine oil system requires a minimum of approximately 8.98 quarts of oil to generate an oil
level reading and display this on MMI.
Two different oil gauge testers available:
›
›
Note the different adjustment values.
Due to the construction, test gauge scale must face opposite direction of travel to avoid
smudging measurement result.
Audi of America
Winter 2017- 2018
Backup
Oil reservoir
Audi of America
Winter 2017- 2018
Backup
Oil circuit
reservoir
– module in inner V
Engine oil cooler
Coolant temperature
sender G62
Oil temperature sender G664
Oil pressure switch
Audi of America
Winter 2017- 2018
Backup
Oil reservoir
Crankcase
breather
Connection in front of
throttle valve
Non-return valve
Pressure control valve
Fine oil separator
Coarse oil separator
Crankcase breather
V8 TFSI – locating cause for loss of coolant
Audi of America
Winter 2017- 2018
Contents
01.
Customer concern
02.
Known leaks
03.
TSB 2048936
2.1 Connection
TSB 2048936 - 19 Coolant level
warning light on, coolant marks on
coolant pump - 4.0 TFSI
2.2 ITM valve
2.3 Coolant pump housing
04.
Summary
Audi of America
Winter 2017- 2018
Customer concern
Initial situation:
›
Customer concerns about coolant escaping in
vicinity of coolant pump (item 11) and ITM
valve (item 20), with different technical issues
in the field.
Objective:
›
Targeted analysis to find the cause and avoid
incorrect replacement or repeat repairs.
Audi of America
Winter 2017- 2018
Coolant escaping at connection (Item 7)
Audi of America
Winter 2017- 2018
Connection (Item 7)
Problem reported by customer:
›
Coolant loss.
Workshop findings:
›
Traces of coolant in vicinity of coolant pump.
Production measure:
›
Replacement of O-ring material (item 8).
Service procedure:
›
›
It is sufficient to replace the O-ring in the event of leaks!!!
›
Check for leaks at the connection using an endoscope or a mirror (slide 104).
Traces of coolant are often found in the vicinity of the thermostat housing (see next slide, 103).
However, the cause for the escaping coolant is further up at the connection. There have not yet
been any confirmed instances of thermostat housings which are not leak-tight towards the
outside.
Audi of America
Winter 2017- 2018
Traces of coolant on thermostat housing
Audi of America
Winter 2017- 2018
Connection (Item 7)
Audi of America
Winter 2017- 2018
Coolant escaping at ITM valve (Item 20)
Audi of America
Winter 2017- 2018
ITM valve (Item 20)
Problem reported by customer:
›
Coolant loss.
Workshop findings:
›
Traces of coolant in vicinity of coolant pump, on ITM valve.
Production measures:
›
›
›
Optimization of rubber grommet.
Optimization of production process.
Last measures incorporated into production on production date 07/15.
Service procedure:
›
Generally clear traces on ITM valve itself, but also on oil cooler and thermostat housing (see
next slide).
›
Inspect leak with endoscope or mirror.
Audi of America
Winter 2017- 2018
Traces of coolant on oil cooler and sump
Audi of America
Winter 2017- 2018
Coolant escaping at coolant pump housing (Item 12)
If there are traces of coolant on the coolant
pump housing (item 12), this may have two
different causes:
Cause 1:
›
Major leak at coolant pump.
Cause 2:
›
Small leak at cup on coolant pump housing.
Audi of America
Winter 2017- 2018
Cause 1: Significant amount of coolant escaping at
coolant pump housing
›
›
Major leaks at the coolant pump always result in a customer concern.
›
Leaks at the coolant pump are therefore generally secondary damage resulting from
insufficient bleeding of the coolant system or from a faulty ITM valve.
The mechanical seal of the coolant pump develops a fault due to being damaged by air in
the system  running dry (see next slide).
Service procedure:
›
In this case, the coolant pump must be replaced and you must make sure that the ITM valve
is not faulty. The cooling system must then be bled correctly in accordance with ELSA.
Audi of America
Winter 2017- 2018
Faulty mechanical seal (running dry)
Damaged seal
Audi of America
Winter 2017- 2018
Cause 2: Small leak at cup on coolant pump housing
›
The coolant pump housing is sealed at the drive shaft via a mechanical seal. To ensure that
the seal does not run dry, a small amount of coolant leakage is necessary to keep the seal
lubricated (for design-related reasons).
›
Slight traces of coolant on the coolant pump cup can therefore be evaluated as okay (see
photographs on next slide).
›
Such leaks generally do not result in a customer concern and are found as part of a service
inspection or tire change. If there is a slight leak and the coolant level drops significantly,
this issue may occasionally result in a customer concern (coolant level warning lamp lights
up).
Service procedure:
›
In this case, the traces of coolant must be removed and the cooling system must be bled
and checked for leaks in accordance with the Repair Manual. Once this has been done, no
further repairs should be performed if no fresh traces of coolant are visible.
Audi of America
Winter 2017- 2018
Cause 2: Small leak at cup on coolant pump housing
Audi of America
Winter 2017- 2018
TSB 2048936
Refer to TSB 2048936: 19 Coolant level warning light on, coolant marks on coolant
pump - 4.0 TFSI .
›
Documenting the concern in detail using the checklist in this bulletin assists Product Support in
analysing new concerns in the field.
Audi of America
Winter 2017- 2018
V8 TFSI – locating cause for loss of coolant
Summary
›
›
There are different places in which coolant can escape in the vicinity of the coolant pump.
›
Slight traces of coolant on the cup of the coolant pump housing should be evaluated as okay,
provided that the test showed the cooling system to be free of leaks.
›
All cases should be documented precisely via the TSB’s instructions to assist with quality
improvements.
Traces are generally first noticed on the thermostat housing, sump or underbody guard.
However, the cause is mostly located higher up at the ITM valve or the coolant connection.
Thank you!