NHTSA ID Number: 10122743
Manufacturer Communication Number: Campaign Circula
TSB/Document Date: 2017-11-08
Summary
To ensure that all Audi
R8 services and repairs are performed properly under this action, repair work must be performed at an authorized Audi dealer with the designation Audi R8 Certified Point or Audi R8 Service Point. Under certain driving conditions the MIL may come on even though the vehicle is operating correctly. If the MIL is on because of this issue, your vehicle may not pass an IM (emissions) inspection. As applicable, installation of an engine wiring harness overlay and updated ECM programming.
TCM was found to have been tuned
- Notify the owner that any damage
caused by the tuning of the ECM or
TCM (including any adverse emissions
consequences) will not be covered by
any Audi warranty.
•
Enter the VIN in ElsaWeb and proceed to the
“Campaign/Action” screen.
Tip: On the date of repair, print this
screen and keep a copy with the
repair order.
⇐ Ensure that the Status is “Open” .
⇐ Note the Applicable Criteria ID for use in
determining the correct work to be done and
corresponding parts associated .
Tip: Multiple criteria possible.
Check criteria then proceed to:
• Section B for criterion 04,
• Section E for criterion 03, or
• Section H if only criteria 01 or 02.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 11 of 38
SECTION B – Spyder Preparation – Criterion 04
Vehicles Only
• Write down all of the customer’s radio station
presets.
•
Disconnect battery.
•
Cover and tape the side panels and the
convertible soft top panel.
CAUTION:
This ensures paint damage will be avoided while
assembling and disassembling the service door.
•
Assemble the side panel covers (VAS 6428)
and rear cover (VAS 6411).
•
Remove the oil cap and cover the oil fill
opening.
CAUTION:
Removing oil cap will help prevent damage while
assembling and disassembling the air box.
⇐ Remove the bolt from the secondary air
injection hose .
⇐ Remove the connector from the bracket
and disconnect it.
Tip: Note service door position with masking
tape and marker.
⇐ Free up the wiring harness on the right
hinge .
⇐ Remove the nut .
⇐ Loosen the nut two turns.
•
Repeat on other side.
WARNING:
A second technician is needed to support
and hold the servicing door.
•
Disengage the left and right gas-filled struts for
the servicing door.
⇐ Remove the servicing door from the hinge
with a second technician.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 12 of 38
⇐ The space around the ECMs should be
additionally protected with suitable tape,
especially the edges of the side panels.
•
Remove both rear wheels.
⇐ Remove both left and right rear wheel housing
liners by removing screws .
•
Remove right side air intake snorkel.
⇐ Remove right fender support bracket .
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 13 of 38
⇐ Remove the bolts and press the left
secondary air injection pipe to the side.
•
Repeat on right side of vehicle.
⇐ Remove the air filter housing bolts .
⇐ Remove the boots from the air filter
housing.
•
•
Remove air filter housing with the Mass Airflow
(MAF) sensors.
Tip: Block air intake to prevent any debris from
entering the engine.
⇐ Remove vacuum reservoir hold-down
bolts on right side of engine compartment to
gain better access to wiring harness.
•
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 14 of 38
⇐ The ECM is secured in a protective
housing and shear bolts to
make it more difficult to access.
⇐ The threads of the shear bolts (that are not
installed in ECM) are coated with locking
compound and must be heated to remove.
CAUTION:
The threads of both shear bolts (that
are installed in the ECM) are not coated
with locking compound. The threads in the
ECM housing must not be heated
(unintentional heating the ECM).
⇐ Adjust the settings on the hot air gun (VAS
1978/14A or equivalent) with the temperature
control at the maximum setting and the
two-stage air flow switch set to level 3.
WARNING:
When heating threads of shear bolts,
components of protective housing are
also heated intensely. Do not burn
yourself on this! Make sure that only the
threads are heated as much as possible,
and not any of the surrounding parts.
Grinding and drilling is not permitted.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 15 of 38
⇐ Heat threads on connector-side shear bolts for
approximately 25 to 30 seconds with VAS
1978/15A or equivalent.
⇐ Remove shear bolts with locking pliers (see
direction of ).
Note: The shear bolts installed in the ECM do
not need to be heated for removal. They
should be removed without heat.
•
Repeat for other ECM.
•
The harness requires extra slack to remove
ECM 2 (J624, driver’s side). Unclip harness
hold-downs to provide slack.
CAUTION:
Be careful to not damage harness holddowns while unclipping.
•
Mark ECMs so they are not interchanged;
disconnect and set aside.
WARNING:
The ECMs are not interchangeable.
Reinstalling them in the wrong location
will cause damage.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 16 of 38
⇐ Remove ground wire at ECM 1 (J623,
passenger’s side).
⇐ Release harness holder from frame in right
fender well.
⇐ Pull the harness down through the
frame opening, into the wheel well, to provide
working room for new harness installation.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 17 of 38
⇐ Locate the smaller T60 connector from ECM 2
(J624, driver’s side).
⇐ Remove the tie wrap and release the cover
with a small screwdriver on the smaller T60
(push the lug upwards away from the front of
the plug, ).
⇐ Pull out the terminal lock insert .
(Arrow 1) Lug.
(Arrow 2) Terminal lock.
⇐ The terminal of the engine speed signal (purple
wire) is in the brown housing element, located
in chamber 36. Release the terminal using
VAS1978/7A from the front side of the
connector block, and gently remove wire.
•
Repeat on the right side of vehicle: pull the
purple wire from chamber 36 of the T60
connector on ECM 1.
•
Proceed to Section C only if criterion 05
applies. Otherwise, proceed to Section D.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 18 of 38
SECTION C – Remove Spyder Version 1
Harness – Criterion 05 Vehicles Only
•
Follow the version 1 harness back from ECM 2
and remove any tie wraps that were installed
securing overlay to main engine harness. Do
this all the way to the D90 connection point.
Tip: The D90 connection point of the engine
speed signal wire is located on the right
side of the engine compartment, just in
front of the heat shield.
⇐ Mask the edge of the heat shield
with tape (risk of injury). Push back the
protective hose .
⇐ Remove hold down bolt for the harness holder
. Make sure that the other wires
do not get damaged.
⇐ Locate purple overlay harness wire and cut it
off 5 cm from D90 connection point . Discard the overlay harness; it will no
longer be used.
•
•
Apply shrink tubing to remaining wire from the
D90 connection. Shrink tubing with UT-100SI
Ultratorch (or equivalent) and pinch the end of
the tubing closed. Tape wire back in direction
of the harness.
Proceed to section D.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 19 of 38
SECTION D: Installing Version 2 Harness on
Spyder – Criterion 04 Vehicles Only
⇐ If the version 1 wiring harness was not
installed: cut off wire terminal end and apply
shrink tubing to wire from chamber
36 on both ECM1 & 2. Shrink tubing with UT100SI Ultratorch (or equivalent). Pinch the end
of the tubing closed and tape
wire back in direction of the harness.
Note: The version 1 wiring harness is a
previous repair that was not done on all
vehicles.
•
Remove the brown wire for the G28 engine
speed signal to the T60 connector on ECM 1
(J623, passenger’s side) from chamber 51
using VAS 1978/7A.
⇐ Cut off wire terminals and apply shrink tubing
on each wire. Then, heat tubing
with UT-100SI Ultratorch (or equivalent) and
pinch the end of the tubing closed. Tape wires
back in direction of the harness.
⇐ Strip the harness at the right side inside the
wheel well, where the harness branches, and
locate the D141 connection .
CAUTION:
Do not confuse with any other connection in
harness.
•
Locate the D141 connection in engine wiring
harness near the harness junction where the
harness branches to the T60 and T94 ECM
connector plugs. The D141 connection has five
lilac (purple) and one wire that is black or gray.
Do not confuse with any other connection in
harness.
Tip: The D141 connection can be in slightly
different locations on each wiring
harness. In many cases, you can locate
it by squeezing the harness before
removing any tape.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 20 of 38
⇐ Cut off the wire that is black or gray about 5 cm
behind the crimp. The new harness will be
connected to the remaining section of black
wire from the D141 connection. Apply shrink
tubing to the harness section of the black wire
and heat tubing with UT-100SI Ultratorch (or
equivalent). Pinch the end of the tubing closed
and tape back in direction of the harness.
⇐ Disconnect the connector to the G28
engine speed sensor on the left side of the
transmission bell housing and cut off the
connecter end as straight as possible. The
original wiring to the sensor is no longer
required.
⇐ Seal the G28 cable opening with silicone
sealant.
•
Put the G28 plug of the repair harness on the
engine speed sensor and tie wrap (N 909 377
02) following the original G28 harness. Keep
harness away from sharp objects and the
exhaust.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 21 of 38
⇐ The overlay harness should be routed along
the main engine harness .
⇐ At ECM 1 (J623, passenger’s side): plug the
purple wire into chamber 36 and the brown wire
into chamber 51 of the small plug (T60).
Note: Keep wires twisted as far as possible
and pull on wires to ensure they are
locked into connector.
•
•
•
•
Reinstall terminal locking tab.
Tape harness with cloth tape (000 979 950).
Reinstall connector cover.
Install tie wrap (N 909 377 02).
⇐ Crimp the black wire from the D141
connection to the new wire from the overlay
harness. Use crimping pliers VAS 1978/1-2
with exchangeable head VAS 1978/1-1. Use
yellow crimping slot 0.35-2.5mm and crimp
connecter (000 979 940). Heat connector with
UT-100SI Ultratorch (or equivalent).
•
Install any harness covering that may have
been removed and tape over exposed wires.
⇐ Mark splice location with a wrap of yellow tape
on outside of harness.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 22 of 38
⇐ Route the overlay to ECM 2. Follow
the harness through the splash shield into the
wheel house.
•
For ECM 2 (J624, driver’s side), put the purple
wire into chamber 36 of the T60 plug. Pull on
the wire to ensure that it is locked into the
connector.
•
Install terminal locking tab.
•
Tape harness with cloth tape (000 979 950).
•
Reinstall connector cover.
•
Install tie wrap (N 909 377 02).
•
Install tie wraps (N 909 377 02) every 8 inches
following main engine harness. Do not
overtighten.
⇐ Connect ECM 1 to both wiring harnesses.
Reconnect ECM holders and with new
shear bolts (N 910 238 02) and (N 909
803 04 with locking compound), then reinstall.
⇐
CAUTION:
Be sure to install shear bolts with
locking compound into the correct position.
Put the shear bolts without locking
compound into the ECM.
•
Repeat on other side.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 23 of 38
⇐ Reconnect ground from ECM 1.
⇐ Secure ECM with locking tabs and
put cover back in position on both sides of
vehicle.
⇐ Carefully reinstall air filter housing with MAF.
Secure with bolts and torque to 8
Nm.
•
Reconnect air snorkel on left.
•
Reconnect all hoses with hose clamps.
Tip: Block air intake to prevent any debris from
entering the engine.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 24 of 38
⇐ Reconnect the left secondary air injection tube
with 2 bolts .
•
Uncover the oil fill opening and put the oil cap
back into position.
⇐ Put harness holder back on frame (picture
shows removal).
•
Reinstall fender support bracket
•
Reinstall the air snorkel on the right side.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 25 of 38
⇐ Reinstall fender liners with bolts
torqued to 4 Nm.
•
Reinstall wheels and torque wheel bolts to 120
Nm.
⇐ Reinstall servicing door with help from a
second technician. Position the door on the
hinges using the masking tape markings you
made during removal. Torque the nuts and
to 23 Nm.
•
Reinstall gas filled struts and ensure clip is
engaged.
⇐ Reattach wiring harness to hinge .
•
Remove all protective tape from both sides.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Audi dealer. 2012 Audi of America LLC and Audi Canada. All Rights Reserved.
October 2012
24U8/K9/Revised Page 26 of 38
⇐ Reconnect connector , then put back into
bracket ensuring that it is clipped into
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TSB/Document ID: Campaign Circula
Replacement Service Bulletin Number:
MFR Communication Date: 2012-10-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
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