A2122392044640_1

Technical Service Bulletin
21 Engine difficult to start, turbocharger is damaged - V8 4.0TFSI
21 22 39 2044640/12 March 3, 2022. Supersedes Technical Service Bulletin Group 21 number 21-38 dated
December 16, 2021 for reasons listed below.
Model(s)
Year
A8, S6, S7,
and S8
2013 - 2016
RS 7
2014 - 2016
S8+, RS 7+
2016
VIN Range
All
A8
000001 - 019190
S8, S8+
000001 - 901368
S6, S7
2017
RS 7, RS
7+
Vehicle-Specific Equipment
4.0L Engine
000001 - 115286
000001 - 904264
Condition
• 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.
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.
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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
• 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://audi-academy.kzoplatform.com/player/medium/1186073779801953796
(Figure 1).
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 Checklist 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
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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
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 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.
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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
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.
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 up to 10 Years/120,000 Miles
Service Number:
2130
Damage Code:
0010
Labor Operations:
Turbocharger replace (1 or 2)
2130 5671
See SRT with
Or
associated
2130 5571
operations
Oil pressure check
1703 0199
80 TU
Check intake and exhaust system for
2130 0199
20 TU
debris, additional time is included in
Turbocharger remove + reinstall
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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
Remove + reinstall oil strain and check
1726 2099
70 TU
1701 0199
10 TU
1701 1799
40 TU
valve
Check that the oil bypass valve is fitted
correctly
Engine oil and filter change - once
OR
Engine oil and filter change – twice. Flush 1701 1799
100 TU
oil circuit
Both Turbochargers remove + reinstall
2130 2071
See SRT with
associated
operations
OR
Left turbocharger remove + reinstall
2130 1971
See SRT with
associated
operations
OR
Right turbocharger remove + reinstall
2130 1972
See SRT with
associated
operations
Air intake distributor remove + reinstall
2446 1921
Or
2446 1971
Or
See SRT with
associated
operations
2446 1923 (RS7
only)
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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
Night vision Camera System adjustment
9080 1550
(if equipped)
See SRT with
associated
operations
Radar sensor adjustment (if equipped)
9163 1650
See SRT with
associated
operations
Overhead view camera adjust (if
9083 1550
equipped)
See SRT with
associated
operations
Diagnostic Time:
GFF
0150 0000
Time as stated on
the diagnostic
protocol (Max 150
TU)
Claim Comment:
Road test prior to service procedure
0121 0002
10 TU
Road test after service procedure
0121 0004
10 TU
As per TSB 2044640/12
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
01 or 02
079103175C
Check valve
01
079115175G
Oil strainer
01
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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
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:
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
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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
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
Coolant additive
01
Outside material
Distilled water (obtained locally)
Shop supply
See ETKA
Fasteners, Bolts, Nuts, and Screws as needed per the
See ETKA/ELSA
Catalogue
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
VAS6096
Cooling system charge unit
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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
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.
©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 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.