A0123682064398_3

Technical Service Bulletin
01 MIL on, DTC P040100 is stored in the ECM - TDI
01 23 68 2064398/3 August 11, 2023. Supersedes Technical Service Bulletin Group 01 number 23-63 dated July
25, 2023 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A3 TDI
2010 – 2013
All
Not Applicable
Condition
REVISION HISTORY
Revision
Date
Purpose
3
-
Revised Required Parts and Tools (Updated part number)
2
07/25/2023
Revised documents (Added attachment)
Revised Required Parts and Tools (Updated part numbers)
1
07/07/2023
Initial publication
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.
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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
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:
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).
• 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).
© 2023 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
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
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:
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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
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:
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.
© 2023 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
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.
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).
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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 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:
• 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.
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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
• 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.
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.
© 2023 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
• 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.
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 2064398/3
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
© 2023 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
Always check with your Parts Department and/or ETKA for the latest information and parts bulletins.
Part Number
Part Description
Quantity
1K0254708GX
DPF
1
1K0253115AE
Seal
2
1K0253725
Clamp
1
1K0253725B
Clamp
1
1K0253120B
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
N10528602
Bolt
4
N91143301
Bolt
2
N91167101
Bolt
1
N91066101
Bolt
1
WHT000729A
Bolt
3
WHT000431A
Bolt
2
N91039802
Bolt
3
1K0825951
Bolt
3
Tool Number
Tool Description
VAG 1687
Charge Air System Tester
KLI9210
EVAP system leak detector
© 2023 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
Freeze Spray
Obtained Locally
VAS 6160/VAS 6150
VAS tester with the current version of ODIS (Windows 10)
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.
© 2023 Audi of America, Inc.
Page 10 of 10
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.