A011919203300119

01 MIL on, DTC P0491 and P0492 stored at the same time in the ECM
01 19 19 2033001/19 July 17, 2019. Supersedes Technical Service Bulletin Group 01 number 19-02 dated
January 25, 2019 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A6
2009 - 2016
All
3.2 FSI AVS and 3.0 TFSI
A7
2013 - 2016
All
3.2 FSI AVS and 3.0 TFSI
S4
2010 – 2012,
2014 - 2016
All
3.2 FSI AVS and 3.0 TFSI
A8, Q7
2011 - 2016
All
3.2 FSI AVS and 3.0 TFSI
A5, S5
Cabriolet,
and Q5
2010 - 2016
All
3.2 FSI AVS and 3.0 TFSI
Condition
REVISION HISTORY
Revision
Date
Purpose
19
-
Revised header (Added model)
Revised Warranty (Added and updated Labor Operations)
18
01/25/2019
Revised Warranty (Updated Labor Operations)
17
12/13/2018
Revised Warranty (Updated Labor Operation)
Customer states:
 MIL on.
Workshop findings:
 Mileage is greater than 15,000 miles.
Both of the following DTCs are stored in the engine control module (ECM), J623 (address word 0001):
 DTC P0491 (Secondary Air System Insufficient Flow, Bank 1).
 DTC P0492 (Secondary Air System Insufficient Flow, Bank 2).
Page 1 of 13
© 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 Background
Under certain driving conditions, the secondary air ports in the cylinder head can accumulate carbon over time,
causing a restriction.
Production Solution
Not applicable.
Service
Please note that before performing this repair for the first time, it is mandatory that the technician complete Audi
Academy Course #940134 and assessment #940134B. Otherwise, the warranty claim will be denied. The
course and assessment can be found on the Audi Academy CRC site. Specific video sections are referenced in
the instructions below.
Perform ODIS Testing – For all but A6 (C6) 3.2FSI and Q7 3.0T:
1.
Delete all DTCs. Bring the engine to operating temperature.
2.
Go to Control Modules >> 01 Engine Control Module >> Control module OBD>> Basic Settings >>
Checking Secondary Air System.
3.
Select MVB: MASS_SA_REL[0] and MASS_SA_REL[1].
4.
Perform test (Press brake and gas pedal at the same time, start test on ODIS tester).
5.
While the Basic Setting test is running, check if the secondary air pump runs normally (no unusual noises).
In addition, check for a leak in the secondary air hose routing between the pump and combi valves.
6.
Immediately after the test is complete, read MASS_SA_REL[0] and MASS_SA_REL[1]. Depending on
the software level and engine code, the air mass flow will be displayed in one of two ways:
 For the old software version:
If the value is between 0.1 and 0.7, and there were no issues with the pump and hoses, the system
needs to be cleaned. Follow the instructions below.
 For the new software version:
If the value is between 13 and 16, and there were no issues with the pump and hoses, the system
needs to be cleaned. Follow the instructions below.
Perform ODIS Testing – For A6 (C6) 3.2FSI and Q7 3.0T only:
1.
Go to Control Modules >> 01 Engine Control Module >> Control module OBD>> Basic Settings >> test 77.
Page 2 of 13
© 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.
2.
While performing test 77, check if the secondary air pump is running and make sure it does not make any
abnormal or unusual noise:
 If test 77 fails but the pump is running and does not make any abnormal/unusual noise, perform the
cleaning process below.
 If the pump is not running or if it makes an abnormal/unusual noise, this TSB does not apply.
Tip: Always use the latest version of this TSB.
Prepare the Vehicle for Power Washing:
1. Move the exhaust sliding
bushings (that connect the
catalytic converter and muffler)
back, then lower the catalytic
converter pipes (Figure 7).
For Q7, unbolt muffler from the
catalytic converter. Cover
mufflers with a plastic bag to
prevent water from entering.
Cleaning water will drain out of
the catalytic converter pipes
during the cleaning process.
Figure 7. Lowered catalytic converter pipes.
2. Remove all spark plugs and cover the engine harness plugs for the coils (for water protection).
3. Drain the coolant so that it can be reused.
4. Bring the front end of the car into service position (for Q5, A6, A8, S4, and S5 Cabriolet) to make room in the
front of the engine. The Q7 has enough room for access to the front of the cylinder heads.
Page 3 of 13
© 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.
5. For 3.0T only: remove the
coolant supply lines (intercooler
of the supercharger) in the front
of the engine (Figure 8).
Figure 8. Front coolant pipes to be removed for 3.0T.
6. Remove the following components:
 Coolant pipe (Figure 9,
image 1).
 Coolant flange (Figure 9,
image 2).
 Pulley and if needed
bracket, of power steering
pump (Figure 9, image 3).
 Pulley of the water pump
(Figure 9, image 4).
 Coolant tube (Figure 9,
image 5).
 Dipstick tube (Figure 9,
image 6).
Figure 9. Engine component removal.
Note:
When removing the dipstick tube, turn it 180 degrees, and then reinstall it for water protection.
Page 4 of 13
© 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.
Note:
To loosen the coolant tube, remove 2 bolts (Figure 10, image A and C), open clip
(Figure 10, image B), and pry bushing apart as shown in training video (Figure
10, image D). There is no need to loosen the AC compressor.
Cover opening of right coolant pipe to prevent coolant circuit contamination.
Figure 10. Loosening the
coolant tube.
7. Remove the main port freeze
plug by hitting the marked area
with a small punch until it turns
(Figure 11). Remove with
pliers.
Figure 11. Marked area on main port of freeze plug.
Prepare to Power Wash Tool Setup:
Warning:
 Read the pressure washer user manual and follow these safety instructions.
 Always insert special cleaning hose into adaptor and engine before turning pressure washer on.
 If switching special cleaning to a different port, turn pressure washer off and release residual pressure by
pulling the trigger before removing the special cleaning hose from the engine.
Wear safety glasses and gloves.
1. Become familiar with the special tool set VAS6825 (Figure 12):
Page 5 of 13
© 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.
 Special hose with scale for cleaning
single ports (Figure 12, image 1).
 Special hose for cleaning the main
ports (Figure 12, image 2).
 Hose adaptor for the special hose
with scale (Figure 12, image 3).
 Engine adaptor for bank one (Figure
12, image 4a).
6
 Engine adaptor for bank two (Figure
12, image 4b).
Figure 12. Special tool set VAS6825.
2. To catch water, put a pan under the front of the engine and under the disconnected catalytic converter pipes.
3. Install engine adaptors on the
appropriate banks (Figure 13 and Figure
14).
Figure 13. Engine adaptor on bank one.
Page 6 of 13
© 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.
Figure 14. Engine adaptor on bank two.
4. To ensure proper pressure washer function, use a ¾-inch water supply hose (no longer than 60 feet) to
supply pressure washer.
The Audi-supplied pressure washer comes with a 22mm male-to-male adapter (to connect the special tool to
trigger gun), a pressure gauge (to connect between pressure washer and high-pressure hose), and a 220V
power adapter.
Make sure that pressure is at least 1800 psi when using the special single port cleaning hose (the hose with
the scale). Use the table below to compensate for low water pressure:
psi While Cleaning Single Ports
Cleaning Time in Minutes
Less than 1900
Pressure too low – check the water supply
1900
4
2000 or higher
3
Power Wash the Ports:
Cleaning Main Secondary Port:
1. Insert special main port cleaning hose (the hose without the scale) two inches into the engine adaptor.
2. Turn the pressure washer on.
3. Holding the cleaning hose tightly, pull the pressure washer trigger.
4. Gradually move the cleaning hose into the port, going back and forth until the combi valve is reached. All
water comes out at adaptor #4.
5. Continue going back and forth through the whole port until only clean water drains out of the cylinder head.
Page 7 of 13
© 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.
6. Do the same with the other cylinder head.
Cleaning Single Ports:
1. Because every port has a different distance to the cylinder head, use the table below to position the hose
adaptor for the special single port cleaning hose (the hose with the scale) correctly into the hose. The back
side of the hose adaptor must align with the number on the scale of the cylinder to be cleaned (Figure 15).
The longitudinal slot on the hose adaptor must align with the black line on the scale for correct rotational
positioning (Figure 15).
Dimensions Port 1
2
3
Bank One
10.5
19.5
28.5
Bank Two
13.7
22.7
31.8
Figure 15: Arrow indicating how the back side of the adaptor must align with the scale. The red dotted line
indicating how the longitudinal slot must align with the black line on the scale.
2. After adjusting the position of the hose adaptor,
insert the special single port cleaning hose into the
hose adaptor, and bring it back into locking position
(Figure 16).
Figure 16. Locking position/transverse longitudinal
movement and of the hose adaptor
3. While cleaning, make sure that the pressure washer is supplying pressure greater than 1800 psi.
Page 8 of 13
© 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.
4. Based on the washer’s pressure, clean the port based on the table below. While cleaning, continuously move
the hose adaptor within the longitudinal and transverse slots (Figure 16).
Psi While Cleaning Single Ports
Cleaning Time in Minutes
Less than 1900
Pressure too low – check the water supply
1900
4
2000 or more
3
Tip: After ten seconds of cleaning, all of the water should be draining out of the exhaust. If water is draining
out of the engine adaptor, check the position of the hose adaptor on the hose.
5.
Do the same for all remaining cylinders.
6.
It is recommended that after cleaning, all single ports
are checked with snap-on boroscope BK6000 (or
similar, with 90-degree lens), to make sure all ports
are clean (Figure 17).
Figure 17. Clean single port.
7.
When all carbon is removed, install a new main port plug using an 8mm socket with a short extension,
paying special attention to install it squarely. The outer edge of the plug should be recessed ~0.5mm – 1mm
behind the outer cylinder head edge.
8.
Reinstall all components (except spark plugs) and fill the system with coolant according to ELSA.
9.
Using a vacuum extractor, remove all water from all combustion chambers.
10. Make sure all water is removed from the combustion chambers by using the self-start function twice
while the spark plugs are still removed (cover spark plug openings with a towel). Install spark plugs and
coils.
Page 9 of 13
© 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.
Make sure water is completely drained out of the exhaust (make sure the exhaust is lowered enough).
Tip: There is no need to replace the engine oil; almost no water drains into the oil pan.
11. Allow the car to run at idle for 15 minutes to ensure that any remaining in the exhaust system evaporates.
After Power Washing:
1.
Delete all DTCs. Bring engine to operating temperature.
2.
Go to Control Modules >> 01 Engine Control Module >> Control module OBD >> Basic Settings >>
Checking Secondary Air System.
3.
Select MVB: MASS_SA_REL[0] and MASS_SA_REL[1].
4.
Perform test (Press brake and gas pedal at the same time, start test on ODIS tester).
5.
Immediately after the test is complete, read MASS_SA_REL[0] and MASS_SA_REL[1].
 For the old software version:
If the value is between 0.9 and 1.0, the cleaning was successful.
 For the new software version:
If the value is between 0 and 5, the cleaning was successful.
Warranty
Claim Type:
 1EB – Verify Vehicle Warranty Coverage.
 If the vehicle is outside any warranty, this Technical Service Bulletin is
informational only.
Service Number:
2644
Damage Code:
0010
Labor Operations:
Coolant pipe remove + reinstall
1961 1906 (Q5 CALB, CTUC,
& CTUD, A6 CALA, and A5
CALA)
Or
1961 1941 (A6 CCAA, A6/A7
CGXB, A6/A7 CTUA, S4, S5,
S5 Cab CCBA, and A8
CTUB)
See SRT
Or
Page 10 of 13
© 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.
1961 2039 (Q7 CJWE, CJWC,
CJWB, and CTWB)
Power steering pump remove +
reinstall (overlap reduced includes
time for exhaust and spark plugs)
4898 1999 (Q5 CALB, CTUC,
CTUD, A6 CCAA & CALA,
A6/A7 CGXB, A5 CALA, A8
CTUB, S4, S5, S5 Cab
CCBA, Q7 CJWE, CJWC,
CJWB, and CTWB)
60 TU
Or
2870 2099 (A6/A7 CTUA)
Loosen/fasten lock carrier (Except
Q7 CJWE, CJWC, CJWB, and
CTW)
5038 0950 (Q5 CALB, CTUC,
& CTUD, A6 CCAA & CALA,
A5 CALA, S4, S5, S5 Cab
CCBA, and A8 CTUB)
See SRT
Or
220 TU
Or
5038 0999 (A6/A7 CGXB)
Or
290 TU
Or
5038 0999 (A6/A7 CTUA)
Pressure wash
2644 1999 (All)
75 TU
ACC Calibration
Note:
The following labor operations only
apply if the vehicle is equipped with
ACC. Only claim these labor
operations if applicable and if
necessary.
Radar sensor adjust (if equipped)
See Elsa
See SRT
9163 1550 (Q5 CALB, CTUC,
& CTUD, S4, S5, S5 Cab
CCBA, A6 CCAA & CALA,
A5 CALA and Q7 CJWE,
CJWC, CJWB, & CTWB)
See SRT
Or
9163 1650 (A6/A7 CGXB,
A6/A7 CTUA, and A8 CTUB)
Preparation Driver Assist Calibration
9092 0051 (All)
See SRT
Page 11 of 13
© 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.
Vehicle front + rear measure
4495 0350 (All)
See SRT
Front wheel track adjust
4488 1550 (All)
See SRT
Rear wheel track adjust
4493 1550 (All)
See SRT
Front wheel camber adjust
4489 1550 (Q5 CALB, CTUC,
& CTUD, Q7 CJWE, CJWC,
CJWB, & CTWB, A6/A7
CTUA, A6 CALA & CCAA,
A5 CALA, A6/A7 CGXB, A8
CTUB, and S4/S5 CCBA)
See SRT
4494 1550 (Q5 CALB, CTUC,
& CTUD, A6 CALA & CCAA,
A6/A7 CTUA, A5 CALA,
A6/A7 CGXB, A8 CTUB, Q7
CJWE, CJWC, CJWB, &
CTWB and S4/S5 CCBA)
See SRT
Rear wheel camber adjust
Camera f night vision sys adjusted (if 9080 1550 or See Elsa
equipped)
Diagnostic Time:
Claim Comment:
See SRT
GFF – Checking and clearing fault
codes included in existing labor
operations
0150 0000
Time stated
on diagnostic
protocol (Max
40 TU)
Road test prior to the service
procedure
0121 0002
10 TU
Road test after the service procedure 0121 0004
10 TU
As per TSB #2033001/19
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
Page 12 of 13
© 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.
Always check with your Parts Department and/or ETKA for the latest information and parts bulletins.
Part Number
Part Description
Quantity
06E121119A or 06E121119E
O-ring cross pipe (3.2L and 3.0L respectively)
02
See ETKA
O-ring cross pipe (3.0L A8)
02
N 0119078
Freeze plug
02
06E121139E or 06E121139H
Seal coolant flange (3.2L and 3.0L respectively)
01
See ETKA
Seal coolant flange (3.0L A8)
01
G 013A8J1G
Coolant
0.5
06E121119C
O-ring cross pipe to therm (3.0L only)
01
See ETKA
Steering Power Fluid
See ELSA
See ETKA
Fasteners, Bolts, Nuts, and Screws as needed per See ETKA/ELSA
the Repair Manual
Tool Number Tool Description
VAS6825
Tool set
VAS6825/1
Adaptor set
Not applicable Pressure washer
Additional Information
All parts and service references provided in this TSB (2033001) are subject to change and/or removal.
©2019 Audi of America, Inc. All rights reserved. The 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 13 of 13
© 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.