A2120352059258_1

21 Engine difficult to start, turbocharger is damaged - Repair Authorization
21 20 35 2059258/1 April 28, 2020.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
S6, S7
2017
115286 - 999999
4.0 TFSI
A8
2017
019190 - 999999
4.0 TFSI
S8
2017
901386 - 999999
4.0 TFSI
RS7
2017
904511 - 999999
4.0 TFSI
S6, S7, A8,
and RS7
2018
All
4.0 TFSI
Condition
Customer states:
 The engine cannot be started or only with difficulty.
 The engine makes unusual noises when accelerating.
 The engine has reduced performance.
Workshop findings:
 Damage on turbocharger impeller fins causes increased free play on impeller shaft of the turbocharger or there
is a broken impeller shaft.
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 to the turbocharger.
Page 1 of 7
© 2020 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:
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
No changes to production have been made, as no issue has been identified.
Service
Audi of America is requesting your cooperation in supplying us with technical information regarding this condition.
1.
Verify the condition.
Watch the June Hot Topics before proceeding with the below
repair at: https://audiacademy.kzoplatform.com/player/medium/11860737798019
53796 (Figure 1).
Figure 1. QR Code for supporting video.
2.
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 key.
All information must be documented with pictures with the attached Checklist completely filled out and
stored with the Repair Order.
3.
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).
Perform a visual check of the engine control unit (check
for irregularities of the housing of the control unit) and
check whether a tuning box is fitted (also in the area
behind the diagnostic interface).
4.
Figure 2. Correct hardware version number
Check the intake tract for leaks. Review the repair history for possible previous repairs on the intake tract.
Page 2 of 7
© 2020 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.
Measure the oil pressure at idle and 2000 rpm according to Elsa.
6.
Visually assess the condition of the damaged turbocharger from both sides. No oil marks (charge air and
exhaust side) could be another indication for poor oil supply to the turbocharger.
7.
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.
8.
Check the installation of the oil filter bypass valve according to service measure 17F2.
Note:
This TSB is not replacing any Repair Manual instructions, this TSB is meant to supplement the Repair
Manual. See Elsa, Engine >> 8-Cylinder Direct Injection 4.0L 4V TFSI Engine >> 21 Turbocharger >>
Turbocharger, Removing and Installing.
9.
If the vehicle is within the New Vehicle Limited Warranty, contact a TAC consultant before proceeding
with the instructions below. Please attach the DTC and diagnostic log to the TAC ticket.
10.
Replace the turbocharger as well as the oil strainer and check valve in the inner valley of the engine
according to Elsa and observe all instructions, including:
 Check the oil supply line for through flow and oil deposits.
 Check the oil drain hoses for through flow and oil deposits.
 Filling the turbocharger at the supply line connections with engine oil.
Replacement of the turbocharger wastegate vacuum actuator is no longer necessary. The vacuum actuator
and actuator rod can be reused. The existing clip must not be reused and must always be replaced. The
retaining clip is now available in ETKA.
11.
Change the engine oil including the oil filter. Check the drained oil and oil filter for particles. If particles are
found, flush the engine and new turbocharger with the new engine oil at an increased engine speed for 15
minutes.
 If no particles were found in the drained engine oil or oil filter, another oil change is not necessary and
the engine does not have to be flushed at an increased idle speed.
 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 Elsa instructions may lead to premature turbocharger failure which may be
reviewed by Warranty.
Page 3 of 7
© 2020 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:
Warranty may review the claim and request the turbocharger(s), the oil strainer and the check valve that
were replaced. 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 the 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 the oil bypass valve is fitted
correctly
1701 0199
10 TU
Engine oil and filter change - once
1701 1799
40 TU
Engine oil and filter change – twice. Flush
oil circuit
1701 1799
100 TU
Left Turbocharger remove + reinstall
2130 1971
See SRT
Right Turbocharger remove + reinstall
2130 1972
See SRT
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
© 2020 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.
Diagnostic Time:
Air intake distributor remove + reinstall
without night camera and radar sensor
(RS7 only)
2446 1923
See SRT
Night vision Camera System adjustment (if
equipped)
9080 1550
See SRT
Radar sensor adjustment (if equipped)
9163 1650
See SRT
Overhead view camera adjust (if equipped) 9083 1550
See SRT
GFF
0150 0000
Time as stated on the
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 # 2059258/1
Claim Comment:
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
079145769
Wastegate rod retaining clip
02
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
Page 5 of 7
© 2020 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.
079129717K
Intercooler housing gasket (Right)
01
079129717J
Intercooler housing gasket (Left)
01
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
(Campaign 21F2 addresses this).
WHT006537
Turbo coolant pipe o-rings lines (black 2.8mm)
04
Note:
Installed seals are based on which pipes are installed
(Campaign 21F2 addresses this).
WHT001011A
Coolant supply pipe lower o-rings yellow 12.2x1.65
02
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 or 02 if flush is required
G 013A8J1G
Coolant additive
01
Outside material
Distilled water (obtained locally)
Shop supply
Page 6 of 7
© 2020 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.
See ETKA
Fasteners, Bolts, Nuts, and Screws as needed per the
Repair Manual
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 B
Refractometer
GRX3000VAS
Approved battery charger
See ETKA/ELSA
Additional Information
All parts and service references provided in this TSB (2059258) are subject to change and/or removal.
©2020 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 7 of 7
© 2020 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.