A2121372044640_1

21 Engine difficult to start, turbocharger is damaged V8 4.0TFSI
21 21 37 2044640/10 August 31, 2021. Supersedes Technical Service Bulletin Group 21 number 20-36 dated
October 29, 2020 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
RS7
2014 - 2016
All
4.0L
S8+, RS7+
2016
All
4.0L
A8
2017
000001 - 019190
4.0L
S8, S8+
2017
000001 - 901368
4.0L
S6, S7
2017
000001 - 115286
4.0L
RS7, RS7+
2017
000001 - 904264
4.0L
A8, S6, S7,
and S8
2013 - 2016
All
4.0L
Condition
REVISION HISTORY
Revision
Date
Purpose
10
-
Revised Service (Updated Step 1 and 9)
Revised Warranty (Updated Claim Type and Labor Operations)
Revised Required Parts and Tools (Added and updated tool part numbers)
9
10/30/2020
Revised Required Parts and Tools (Updated part number)
8
08/26/2019
Revised Additional Information (Updated resources)
Customer statement:
 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 the impeller shaft of the turbocharger or
there is a broken impeller shaft.
Page 1 of 8
© 2021 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
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 the intake tract allowing outside unfiltered air and debris into the turbocharger.
 Poor oil supply to the 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
the engine. The oil strainer and check valve 079103175C must always be replaced to ensure proper oil
flow to the turbochargers.
Service
Watch the June Hot Topics 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 8
© 2021 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.
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 the warranty key.
 All information must be documented with pictures with the attached Checklists completely filled out and
stored with the Repair Order.
2 Check the hardware version of the engine
. control module. An X version indicates that the
engine control module was replaced/or is
modified (Figure 2).
Figure 2. Correct hardware version number.
Perform a visual check of the engine control module (check
for irregularities of the housing of the control module) and
check whether a tuning box is fitted (also in the area behind
the diagnostic interface).
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 Elsa.
.
5 Visually assess the condition of the damaged turbocharger from both sides. No oil marks (charge air and
. exhaust side) could be another indication of 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.
7 Check the installation of the oil filter bypass valve according to service measure 17F2.
.
Note:
This TSB is not replacing any Elsa 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.
8 Replace the turbochargers as well as the oil strainer (do not clean the strainer) and check valve in the
. inner valley of the engine according to Elsa and observe all instructions, including:
Page 3 of 8
© 2021 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.
 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.
9 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.
 Send the oil strainer in a small zip lock bag (do not clean the strainer), back to AoA with the
supplied return address label as soon as the oil strainer is removed. Include a copy of the Repair
Order and both the completed check sheets.
Note:
Failure to follow the TSB and Elsa instructions may lead to premature turbocharger failure which may be
reviewed by Warranty.
Warranty may review the claim and request the turbocharger that was replaced. Documents and pictures
may be requested to be sent to the Warranty Parts Return Center.
Warranty
Claim Type:
 110.
 If the vehicle is outside any warranty, this Technical Service Bulletin is informational
only.
Service Number:
S642
Damage Code:
0010
Labor Operations:
Turbocharger replace
2130 5671
See SRT with
associated
operations
Completing both check sheets
2130 9999
50 TU
Page 4 of 8
© 2021 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:
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
Both turbochargers remove + reinstall
2130 2071
See SRT with
associated
operations
Air intake distributor remove + reinstall
without night camera and radar sensor
2446 1921
See SRT with
associated
operations
Air intake distributor remove + reinstall
without night camera and radar sensor
2446 1923 (RS7
only)
See SRT with
associated
operations
Night vision Camera System adjustment (if
equipped)
9080 1550
See SRT with
associated
operations
Radar sensor adjustment (if equipped)
9163 1650
See SRT with
associated
operations
Overhead view camera adjust (if equipped) 9083 1550
See SRT with
associated
operations
GFF
0150 0000
Time as stated on the
diagnostic protocol
(Max 150 TU)
Road test prior to service procedure
0121 0002
10 TU
Page 5 of 8
© 2021 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.
Road test after service procedure
0121 0004
10 TU
As per TSB # 2044640/10
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
Order by VIN
Turbochargers
(one per bank)
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
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:
Page 6 of 8
© 2021 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.
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
(If 2 required, list
079198405D with qty 2 on the
same line)
See Parts
Catalogue
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
Tool Number
Tool Description
3371
Gauge – Gap adjustment tool
V.A.G 1342
Oil pressure gauge kit
Page 7 of 8
© 2021 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.
V.A.G 1274/8
Adapter
V.A.G 1274/10
Adapter
VAS6096
Cooling system charge unit
T10007B
Refractometer
GRX3000VAS
MRT battery charger
MTRMSP0702
Battery Maintainer
Additional Information
More information can be found at the following resources:
 Elsa, Engine >> 8-Cylinder Direct Injection 4.0L 4V TFSI Engine >> 21 Turbocharger >> Turbocharger,
Removing and Installing.
 Elsa, Systems >> Campaigns/Actions >> Campaign 21F2.
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).
All parts and service references provided in this TSB (2044640) are subject to change and/or removal.
©2021 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 8 of 8
© 2021 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.