A0123602064398_1
Service Bulletin Details
Public Details for: A0123602064398_1
This bulletin provides information for when the mil is on and dtc P040100 is stored in the ecm.
Models from 2013
2013 AUDI A3 |
Models from 2012
2012 AUDI A3 |
Models from 2011
2011 AUDI A3 |
Models from 2010
2010 AUDI A3 |
Technical Service Bulletin 01 MIL on, DTC P040100 is stored in the ECM - TDI 01 23 60 2064398/1 July 7, 2023. Model(s) Year VIN Range Vehicle-Specific Equipment A3 Sportback 2010 - 2013 Not Applicable TDI Condition Workshop findings: The following DTC may be stored in the engine control module (ECM), J623 (address word 0001): • DTC P040100 (Exhaust Gas Recirculation Flow Insufficient Detected). Technical Background High soot loads prior to regeneration can cause possible restrictions in the Exhaust Gas Recirculation (EGR) filter. Tools to assist the technician when checking for charge air system leaks. Production Solution Not Applicable. Service Note: Review the ELSA repair procedures, making certain to address the replacement of fasteners as indicated in the repair manual. Required one-time use items are subject to change and may not be listed. When diagnosing a vehicle with the DTC P040100, P2002, or P240F perform the following: Page 1 of 11 © 2023 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 Service Bulletin 1. Remove the EGR filter from the Diesel Particulate Filter (DPF) and swipe the inside of the exhaust pipe at the EGR filter connection point using a clean cloth or your finger. Figure 1. Checking for carbon. Figure 2. Verifying that there is carbon. 2. If your finger or the cloth comes out with black soot: • Replace the DPF & EGR filter together. The engine must be running correctly with no faults stored to perform the next steps. • Read out 01 ECM control module OBD Basic Settings block 67 with engine at idle and at operating temperature. Select activate and monitor field 3 when EGR is in OFF position. • If the MAF actual value is equal to or greater than 540 mg/h, proceed to smoke testing below (there is likely a leak within the intake system). Page 2 of 11 © 2023 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 Service Bulletin • If the value is less than 540 mg/h, proceed to the inspection of the snow flap and air filter (TSB attachment). There is no need to smoke test. • Smoke test the charge air system for leaks if MAF value is 540 or great (see procedure below). Tip: Proper intake airflow is essential for the longevity of the DPF. If a vehicle is found to have a damaged DPF, it is advised to inspect the condition of the intake air filter and verify resting position of the warm air valve (after the vehicle has cooled, see attachment). If the air filter is dirty, advise replacement. If there is no soot on your finger or the cloth, continue with GFF diagnostics, this bulletin does not apply. Note: When replacing the DPF for the fault P0401, P2002, or P240F it is important to replace both the DPF and the EGR filter together, as soot accumulation in the EGR filter is undesired. It is NOT necessary to replace any other Page 3 of 11 © 2023 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 Service Bulletin components for this fault (i.e. NOx Storage Catalyst, Sulfur Catalyst, Exhaust Flap, EGR Cooler). These components should be reinstalled in the vehicle with the new DPF and EGR filter. If the particulate filter was replaced, an adaptation must be performed in Guided Functions. Note: Vehicles with a front single assembly exhaust (one piece DPF/NOx Cat.) will require additional components. See parts table below. If the car has already had the DPF replaced once, and now has the two-piece DPF/Nox Cat., there is no need for the extra parts. Note: Proper intake airflow is essential for the longevity of the DPF. If a vehicle is found to have a damaged DPF, it is advised to inspect the condition of the intake air filter and verify the resting position of the warm air valve (after the vehicle has cooled) as outlined in “Air Filter, Cleaning Housing and Replacing Filter Element” section of the Elsa Repair Manual. Replace the warm air valve (snow flap) if necessary. Additionally, any leaks within the intake air system will cause additional stress to the DPF and a reduction in engine performance. It is advised to reference Charge Air System Testing 1. The charge air pressure system can be checked using the VAG 1687. Charge air system tester along with the VAG1687/10 adapter as follows: Page 4 of 11 © 2023 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 Service Bulletin 2. Special tool VAG 1687 Charge air system tester, preliminary set-up • Back off pressure regulator knob -2- of VAG 1687 fully to protect gauge when shop air supply is applied to the assembly. • Close valve -3- before gauge. • Close valve -4- after gauge. • Shop air supply line will later be attached to the inlet of VAG 1687. • Remove the “female” fitting from the tester (arrow) and install an appropriate “male” air fitting that will connect to your shop air supply line (See Note below). Note: Use only approved air fittings to adapt shop air supply line to VAG 1687 tester. 3. Special tool VAG 1687/10 pressure adapter, installing. • Separate intake hose from the Mass Airflow Sensor assembly (MAF). • Insert VAG 1687/10 pressure adapter in intake hose -black arrow- using existing clamp (as shown). • Remove crankcase ventilation valve or tube from intake hose at -white arrow-. • Plug hose with appropriate metal plug and hose clamps supplied with VAG 1687 special tool kit at -white arrow-. Note: To help find small leaks, BEFORE pressurizing the system, fill system with smoke using special tool KLI9210 and adapter KLI9210/50 as outlined in this bulletin. An Ultrasonic detector may also be used to detect extremely small leaks where smoke may not be visible. Page 5 of 11 © 2023 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 Service Bulletin Special tool KLI9210 (EVAP system leak detector) • Install optional fitting KLI 9210/50 on hose of special tool KLI9210. • Connect KLI9210 to VAG 1687/1 adapter (KLI 9210 is shown attached to VAG1687/1 at arrow on 1.8L Turbo). Special tool KLI9210 (EVAP system leak detector) • Install optional fitting KLI 9210/50 on hose of special tool KLI9210. • Connect KLI9210 to VAG 1687/1 adapter (KLI 9210 is shown attached to VAG1687/1 at the arrow on 1.8L Turbo). Special tool KLI9210 (EVAP system leak detector), preliminary set-up: • Setup KLI 9210 as described in the user manual regarding selftest and output pressure. • Connect the smoke generator leads to the vehicle battery. • Turn the valve to test (black arrow). • Press the smoke generator button to fill the system with smoke (see instructions printed on the tester). • Check for escaping smoke for two minutes. Tip: Smoke may escape from crankcase hose or oil fill hole. This is normal. With system filled with smoke: Page 6 of 11 © 2023 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 Service Bulletin • Remove smoke generator hose and connect VAG 1687 quickly to prevent smoke from leaking out. • Connect VAG 1687 quickly to prevent smoke from leaking out. Special tool VAG 1687 connecting to pressure adapter 1687/10 • VAG 1687 is shown connected to VAG 1687/10 (black arrow). • Shop air supply connected to VAG 1687 at (white arrow). • Perform pressure test. Performing the Pressure Test: • With outlet the hose -1- of VAG 1687 connected to the air pressure adapter. • Attach the shop air supply line to the previously installed male fitting. • Open valve -3- between regulator valve and gauge. • Adjust test pressure up to 1.0 bar (see Note below) by turning the regulator valve -2-. Note: DO NOT pressurize the system above 1.0 bar. Doing so may force oil into the intake system which can damage the engine. • Slowly open outlet valve -4- (after gauge) to test hose connections. • Observe the pressure gauge for a drop in pressure. Page 7 of 11 © 2023 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 Service Bulletin Tip: Some pressure will be lost past the throttle plate. If a smoke generator was used to fill the system with smoke: • Check for smoke escaping from intake connections. Tip: An Ultrasonic detector may also be used to detect extremely small leaks where smoke may not be visible. • Repair any leaks found. • Remove tester. • Remove plug from crankcase ventilation hose. • Remove air pressure adapter. With VAS diagnostic tool connected: • Erase DTC memory. If a smoke generator was not used to fill the system with smoke: • Apply soapy water solution or equivalent to intake system connections. Tip: An Ultrasonic detector may also be used to detect extremely small leaks. • Inspect intake system connections for leaks. • Repair any leaks found. • Remove tester. • Remove plug from crankcase ventilation hose. • Remove air pressure adapter. With VAS diagnostic tool connected: • Erase DTC memory. • Recheck 01 ECM OBD Basic Settings block 67 at idle with the engine at operating temperature. If the actual MAF value is below 540 mg/h, proceed to the inspection of the snow flap and air filter (attached). If the value is equal to 540 mg/h or greater, refer to Repair Group 21 in Elsa for detailed testing of the charge system components. • If no leaks are found, but Basic Settings block 67 remains at 540 mg/h or above, it is recommended to replace the MAF sensor. Page 8 of 11 © 2023 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 Service Bulletin Warranty Claim Type: If the vehicle is outside any warranty, this Technical Service Bulletin is informational only. Service Number: 2674 Damage Code: 0010 Labor Operations: Remove and install the Particle Filter 2674 1912 See SRT with associated operations. Particle Filter Replace 2674 5562 See SRT with associated operations Diagnostic Time: Check Warm Air Valve 2325 2599 (Snow Flap) Operation, no further action required 10 TU Install new Warm Air Valve (Snow Flap_ 2325 2599 30 TU Smoke Test 2141 2599 70 TU GFF 0150 0000 Time stated on the diagnostic protocol (Max 40 TU) Road test prior to the service procedure No allowance 0 TU Road test after the service 0121 0004 procedure 10 TU Claim Comment: As per TSB 2064398/1 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 9 of 11 © 2023 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 Service Bulletin Always check with your Parts Department and/or ETKA for the latest information and parts bulletins. Part Number Part Description Quantity 1K0254706LX DPF 1 1K02531158AE Seal 2 1K0253725 Clamp 1 1K0253725B Clamp 1 1K0235120B EGR Filter 1 1K0253115AG Gasket 1 1K0253115T Gasket 1 1K0253725E Clamp 1 03G131547H Gasket 1 03G906461C Mass Air Flow Sensor 1 03C0129594E Control Valve (Snow Flap) 1 N10579702 Bolt 3 N91208401 Bolt 4 N91143301 Bolt 2 N91167101 Bolt 1 N91066101 Bolt 1 WHT005350 Escutcheon 2 WHT000729A Bolt 3 WHT000431A Bolt 2 N91039802 Bolt 3 Page 10 of 11 © 2023 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 Service Bulletin 1K0825951 Bolt Tool Number Tool Description VAG 1687 Charge Air System Tester KLI9210 EVAP system leak detector Freeze Spray Obtained Locally VAS 6160/VAS 6150 VAS tester with the current version of ODIS (Windows 10) 3 Additional Information All parts and service references provided in this TSB (2064398) are subject to change and/or removal. ©2023 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 11 of 11 © 2023 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.