A211931 2044640-

Technical Service Bulletin
21 Engine difficult to start, turbocharger damaged V8 4.0TFSI
21 19 31 2044640/6 March 4, 2019. Supersedes Technical Service Bulletin Group 21 number 18-30 dated
November 28, 2018 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A8, S7, S8,
S8+, RS7,
and RS7+
2016
All
4.0L
A8
2017
000001 - 019190
4.0L
S8
2017
000001 - 901368
4.0L
S7
2017
000001 - 115286
4.0L
RS7, RS7+
2017
000001 - 904264
4.0L
Condition
REVISION HISTORY
Revision
Date
Purpose
6
-
Revised Warranty (Updated Labor Operations)
5
11/28/2018
Revised Technical Background (Added Note)
Revised Service (Added QR code and updated Note)
Revised Warranty (Updated Labor Operations)
4
05/22/2018
Revised header data (Added model years)
Customer statement:
 Engine cannot be started or only with difficulty.
 Engine makes unusual noises when accelerating.
 Engine has reduced performance.
Workshop findings:
 Damage on turbocharger impeller fins, increased free play on impeller shaft of turbocharger, or broken impeller
shaft.
Page 1 of 7
© 2019 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 Service Bulletin
Technical Background
Damage to the turbocharger is rarely directly the result of turbocharger failure. Therefore, it is important to
perform further checks to find the root cause, to avoid repeat repairs.
Known causes for turbocharger damage:
 Performance increases by tuned ECM
 Non-compliance with service intervals
 Incorrectly fitted oil filter element
 Leaks in intake tract allowing outside unfiltered air and debris into the turbocharger
 Poor oil supply of turbocharger
Note:
If the vehicle has any DTCs related to the turbocharger boost/regulation the complete GFF Test plan must be
completed and repairs performed before determining if further repairs are necessary.
Production Solution
Optimized oil strainer 079115175G for oil supply lines to turbochargers in the cover in the inner valley of
engine. The oil strainer and check valve 079103175C must always be replaced to ensure proper oil flow to
the turbochargers.
Service
Watch the June Tech Tip before proceeding with the below repair at: https://audiacademy.kzoplatform.com/player/medium/1186073779801953796 (Figure 1).
Figure 1. QR Code for
supporting video.
Page 2 of 7
© 2019 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 Service Bulletin
1 Perform the Guided Functions with the diagnosis tester: "01 check warranty information." Then check for an
. entry with the vehicle data in ELSA under warranty code.
 All information must be documented with pictures and the attached Checklist completely filled out and
stored with the Repair Order.
2 Check the hardware version of the engine control
. unit. An X version indicates that the engine control
module was replaced/or is modified (Figure 2).
Figure 2. Correct hardware version number.
3 Check the intake tract for leaks. Review the repair history for possible previous repairs on the intake tract.
.
4 Measure the oil pressure at idle and 2000 rpm according to ElsaPro.
.
5 Visually assess the condition of the damaged turbocharger from both sides. No oil marks (charge air and
. exhaust side) could be another indication for a poor oil supply to the turbocharger.
6. Check the oil filter for correct installation and correct filter part number 079115561J. If the oil filter is not
centrally fitted, the engine oil may not be filtered, entering the oil supply of the turbocharger due to the
crooked position of the oil filter element.
 Check the installation of the oil filter bypass valve according to service measure 17F2.
 Check the oil supply line for through flow and oil deposits.
 Check the oil drain hoses for through flow and oil deposits.
Note:
This TSB is not replacing any Repair Manual instructions, this TSB is meant to supplement the Repair Manual.
See ElsaPro, Engine >> 8-Cylinder Direct Injection 4.0L 4V TFSI Engine >> 21 Turbocharger >> Turbocharger,
Removing and Installing.
7. Replace both of the turbochargers as well as the oil strainer and check valve in the inner valley of engine
according to ElsaPro and observe all instructions.
8. Change the engine oil including oil filter.
9. Follow the installation instructions in ElsaPro for the turbochargers exactly including:
Page 3 of 7
© 2019 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 Service Bulletin
 Filling the turbocharger at the supply line connections with engine oil.
 To ensure the turbocharger is supplied with enough oil, let the engine run at idle for approximately one
minute after starting, do not increase rpm.
Note:
Failure to follow the TSB and ElsaPro instructions may lead to premature turbocharger failure which may
be reviewed by Warranty.
Warranty may review the claim and both turbos. Documents and pictures may be requested to be sent to
the Warranty Parts Return Center.
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:
2130
Damage Code:
0010
Labor Operations:
Turbocharger replace
2130 5671
See SRT
Oil pressure check
1703 0199
80 TU
Check intake and exhaust system for
debris, additional time is included in
Turbocharger remove + reinstall
2130 0199
20 TU
Remove + reinstall oil strain and check
valve
1726 2099
70 TU
Check that oil bypass valve is fitted
correctly
1701 0199
10 TU
Engine oil and filter change
1701 1799
40 TU
Turbochargers remove + reinstall
2130 2071
See SRT
Air intake distributor remove + reinstall
without night camera and radar sensor
2446 1921
See SRT
Page 4 of 7
© 2019 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 Service Bulletin
Diagnostic Time:
Claim Comment:
Air intake distributor remove + reinstall
without night camera and radar sensor
(RS7 only)
2446 1923
See SRT
GFF
0150 0000
Time as stated on
diagnostic protocol
(Max 150 TU)
Road test prior to service procedure
0121 0002
10 TU
Road test after service procedure
0121 0004
10 TU
As per TSB # 2044640/6
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
Always check with your Parts Department and/or ETKA for the latest information and parts bulletins.
Part Number
Part Description
Quantity
079103175C
Check valve
01
079115175G
Oil strainer
01
Order by VIN
Left waste gate vacuum unit with actuator rod
01
Order by VIN
Right waste gate vacuum unit with actuator rod
01
079103161Q
Cover Gasket
01
N 90303801
Lower oil supply o-rings 9x1.5 black
02
N 91056801
Upper oil supply o-rings 12x2 black
02
WHT006901A
Oil return o-rings 14.5x2
02
N 90465003
Water tube o-rings 23x2.6
03
N 90409501
Clamp breather hoses
04
079129717K
Intercooler housing gasket right side
01
079129717J
Intercooler housing gasket left side
01
Page 5 of 7
© 2019 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 Service Bulletin
079145818
Throttle body gasket
01
079103583
Breather seals
03
N 90686902
Spring clips 23x12 breather hoses
04
WHT006335A
Turbo coolant pipe o-rings lines (blue 2.0mm)
04
Note:
Installed seals are based on which pipes are installed
(see TSB 2036167).
WHT006537
Turbo coolant pipe o-rings lines (black 2.8mm)
04
Note:
Installed seals are based on which pipes are installed
(see TSB 2036167).
WHT001011A
Coolant supply pipe lower o-rings yellow 12.2x1.65
02
Order by VIN
Left turbocharger
01
Order by VIN
Right turbocharger
01
WHT005529
Inlet pipe o-rings
02
079253039M
Exhaust manifold gaskets
02
N 90894601
Manifold nuts M8
16
G 052112A3
Hot bolt paste 170G
01
4G0253115D
Turbocharger outlet gaskets
02
N 91153902
Turbocharger studs
10
N 91130802
Manifold nuts
10
N 0138495
Drain plug gasket
01
079198405D
Oil filter kit
01
G 013A8J1G
Coolant additive
01
Outside material
Distilled water (obtained locally)
Shop supply
See ETKA
Fasteners, Bolts, Nuts and Screws as needed per the
Repair Manual
See ETKA/ELSA
Page 6 of 7
© 2019 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 Service Bulletin
Tool Number
Tool Description
3371
Gauge – Gap adjustment tool
V.A.G 1342
Oil pressure gauge kit
V.A.G 1274/8
Adapter
V.A.G 1274/10
Adapter
VAS 6096
Cooling system charge unit
T10007 A
Refractometer
Approved battery charger
Additional Information
More information can be found at the following resources:
 ElsaPro, Engine >> 8-Cylinder Direct Injection 4.0L 4V TFSI Engine >> 21 Turbocharger >> Turbocharger,
Removing and Installing.
The following Technical Service Bulletin(s) will be necessary to complete this procedure:
 TSB 2028842, 01 Automatic detection of unauthorized chip tuning (TD1 warranty key).
 TSB 2036167, 19 Coolant pipe seepage on turbocharger.
All parts and service references provided in this TSB (2044640) are subject to change and/or removal.
©2019 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 7 of 7
© 2019 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.