A012216203300126

Technical Service Bulletin
01 MIL on, DTC P049100 and P049200 are stored at the same time in the ECM
01 22 16 2033001/26 February 15, 2022. Supersedes Technical Service Bulletin Group 01 number 21-11
dated September 14, 2021 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A5
2009 – 2010
All
V6 Engine
A6 Avant
2009 – 2011
All
V6 Engine
A6, Q5
2009 – 2016
All
V6 Engine
S4, S5
Cabriolet
2010 – 2016
All
V6 Engine
Q7
2011 – 2015
All
V6 Engine
A8
2011 – 2016
All
V6 Engine
A7
2012 - 2015
All
V6 Engine
S5
2013 – 2016
All
V6 Engine
SQ5
2014 - 2016
All
V6 Engine
Condition
REVISION HISTORY
Revision
Date
Purpose
26
-
Revised header (Added engine code)
25
09/14/2021
Revised Required Parts and Tools (Updated Coolant quantity)
24
10/28/2020
Revised Warranty (Updated Labor Operation)
Customer states:
• MIL on.
Workshop findings:
• The vehicle’s 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 P049100 (Secondary Air System Insufficient Flow, Bank 1).
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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
• DTC P049200 (Secondary Air System Insufficient Flow, Bank 2).
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
Note:
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.
Section 1A: 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] or SAF_DIF[1] and MASS_SA_REL[1] or SAF_DIF[2].
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.
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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
6. Immediately after the test is complete, read MASS_SA_REL[0] or SAF_DIF[1] and MASS_SA_REL[1] or
SAF_DIF[2]. 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.
Section 1B: 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.
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.
Section 2: Prepare the Vehicle for Power Washing
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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. 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.
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.
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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
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.
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.
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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
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.
Section 3: 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):
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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
• 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).
6 • Engine adaptor for bank one (Figure
12, image 4a).
• 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.
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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
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 the 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
Section 4: 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.
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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
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.
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.
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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
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.
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.
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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
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 installing 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.
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 water in the exhaust system
evaporates.
Section 5: After Power Washing
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.
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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
3.
Select MVB: MASS_SA_REL[0] or SAF_DIF[1] and MASS_SA_REL[1] or SAF_DIF[2].
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] or SAF_DIF[1] and MASS_SA_REL[1] or
SAF_DIF[2].
• 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, A6
See SRT with
CALA, and A5 CALA)
associated
Or
operations
1961 1941 (A6 CCAA,
A6/A7 CGXB, A6/A7
CTUA, S4, S5, S5 Cab
CCBA & CGXC, A8 CTUB,
and Q5 CTUC & CTUD)
Or
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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
1961 2039 (Q7 CJWE,
CJWC, CJWB, and CTWB)
Power steering pump remove + reinstall
4898 1999 (Q5 CALB,
(overlap reduced includes time for exhaust
CTUC, CTUD, A6 CCAA &
and spark plugs)
CALA, A6/A7 CGXB, A5
60 TU
CALA, A8 CTUB, S4, S5, S5
Cab CCBA & CGXC, Q7
CJWE, CJWC, CJWB, and
CTWB)
Or
2870 2099 (A6/A7 CTUA)
Loosen/fasten lock carrier (Except Q7 CJWE,
5038 0999 (A6/A7 CGXB,
220 TU
CJWC, CJWB, and CTWB)
Q5 CALB, CTUC, & CTUD,
Or
A6 CCAA & CALA, A5
CALA, S4, S5, S5 Cab
290 TU
CCBA, and A8 CTUB)
Or
5038 0999 (A6/A7 CTUA)
Pressure wash
2644 1999 (All)
ACC Calibration
75 TU
See SRT with
associated
Note:
operations
The following labor operations only apply if
See Elsa
the vehicle is equipped with ACC. Only claim
these labor operations if applicable and if
necessary.
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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
Radar sensor adjust (if equipped)
9163 1550 (Q5 CALB,
See SRT with
CTUC, & CTUD, S4, S5, S5 associated
Cab CCBA & CGXC, A6
operations
CCAA & CALA, A5 CALA
and Q7 CJWE, CJWC,
CJWB, & CTWB)
Or
9163 1650 (A6/A7 CGXB,
A6/A7 CTUA, and A8
CTUB)
Preparation Driver Assist Calibration
9092 0051 (All)
See SRT with
associated
operations
Vehicle front + rear measure
4495 0350 (All)
See SRT with
associated
operations
Front wheel track adjust
4488 1550 (All)
See SRT with
associated
operations
Rear wheel track adjust
4493 1550 (All)
See SRT with
associated
operations
Front wheel camber adjust
4489 1550 (Q5 CALB,
See SRT with
CTUC, & CTUD, Q7 CJWE, associated
CJWC, CJWB, & CTWB,
operations
A6/A7 CTUA, A6 CALA &
CCAA, A5 CALA, A6/A7
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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
CGXB, A8 CTUB, and
S4/S5 CCBA & CGXC)
Rear wheel camber adjust
4494 1550 (Q5 CALB,
See SRT with
CTUC, & CTUD, A6 CALA
associated
& CCAA, A6/A7 CTUA, A5 operations
CALA, A6/A7 CGXB, A8
CTUB, Q7 CJWE, CJWC,
CJWB, & CTWB and S4/S5
CCBA & CGXC)
Camera f night vision sys adjusted (if
9080 1550
See SRT with
equipped)
Or
associated
operations
See Elsa
Diagnostic Time:
GFF – Checking and clearing fault codes
0150 0000
Time stated
included in existing labor operations
on the
diagnostic
protocol (Max
40 TU)
Claim Comment:
Road test prior to the service procedure
0121 0002
10 TU
Road test after the service procedure
0121 0004
10 TU
As per TSB 2033001/25
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
© 2022 Audi of America, Inc.
Part Description
Quantity
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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
06E121119A or 06E121119E
O-ring cross pipe (3.2L and 3.0L respectively)
02
See ETKA
O-ring cross pipe (3.0L A8)
02
N0119078
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
See Parts Catalogue
Coolant
01
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
CAM20005MX or equivalent Pressure washer
Additional Information
All parts and service references provided in this TSB (2033001) are subject to change and/or removal.
©2022 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
© 2022 Audi of America, Inc.
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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
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.
© 2022 Audi of America, Inc.
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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.