NHTSA ID Number: 10144668
Manufacturer Communication Number: Circular - Emiss
TSB/Document Date: 2018-09-17
Summary
The Environmental Protection Agency and California Air Resources Board have determined that Audi
A3 vehicles equipped with a 2.0L 4-cylinder TDI engine do not comply with applicable emissions regulations. The emissions control systems on the vehicles will not control emissions under off-cycle conditions as effectively as during the federal test procedure. The extent of the emissions increase under off-cycle conditions depends upon how the vehicles are driven. Phase 2 A&B. Updated work instructions.
Connect hose for warm air intake to air filter
housing.
•
Connect air intake hose to air mas meter
and secure with spring-type clip .
•
Connect connector and secure it. Push on
vacuum hose and clip onto intake hose
.
•
Insert upper part of air duct and push
opposite into fasteners.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 21 of 75
•
Set cover in place and push opposite
into fasteners .
•
Tighten bolts to 2 Nm.
•
Switch on ignition.
•
Check time and adjust, if necessary.
•
Completely open windows, and then completely
close them.
•
Then, with windows closed, pull window regulator
switches until relay can be heard to switch.
•
Check convenience mode of the window
regulators.
o
With convenience closing activated,
windows must close fully without the
need for holding the window regulator
switch.
NOTE
After the voltage supply has been switched back on,
the vehicle must travel several meters before the ESP
warning lamp goes out.
If vehicle REQUIRES installing Emissions Control Module
(Kit 2B):
•
Proceed to Section E
If vehicle DOES NOT REQUIRE replacement of
Emissions Control Module (Kit 2B) at this time:
•
Proceed to Section F for Software Flash
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 22 of 75
Section E – A3 - Install 2.0L Gen 3 Phase 2B Kit
(Emissions Control Module)
NOTE
RISK of Non-payment!
Determining whether or not to install 2.0L Generation 3 Phase II A and/or B is dependent on the specific history
and current mileage of the vehicle. You MUST refer to the IN-FORM tool to identify if one (Kit 2A only) or both
(Kit 2A+2B) Kits are needed! Installing Kit B when only Kit A is needed will result in claim cancellation. Dealers
WILL NOT BE COMPENSATED for this error.
NOTE
STOP!
IMPORTANT!
The following labor operations MUST be followed IN
THE ORDER WRITTEN using care during
removal/reinstallation, handling, and storage of various
components to avoid potential damage. The Exhaust
Pressure Sensors, Reducing Agent Injector,
Exhaust Temperature Sensors, etc. ARE FRAGILE
and can be damaged if proper order of procedures are
not followed, excessive or unnecessary force is used,
or improper handling or storage techniques are utilized.
•
If not already removed at this time, remove the
airbox, battery, battery tray, and lower noise
insulation.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 23 of 75
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
•
Open the heat shield boot .
•
Disconnect the connector .
•
Remove the bolt and gently detach the
Differential Pressure Sensor -G505- from the
mounting bracket. Let the sensor hang freely.
•
Disconnect the connector .
•
Remove the bolt and gently detach the
Exhaust Pressure Sensor 1 -G450- from the
mounting bracket. Let the sensor hang freely.
•
Remove the mounting bracket fastener/s.
•
DO NOT remove the pressure sensors from the
tubes or remove the clamps .
•
You will be instructed to remove the sensors,
mounting bracket, and pipes as an assembly
later in this work procedure.
•
Release the retainers with a screwdriver in
direction of and move the coolant
expansion tank to the side.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 24 of 75
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
•
Loosen the hose clamp .
•
Free up the coolant line and the selective
catalytic reduction lines .
•
Remove the Reducing Agent Injector -N474- and
secure it safely out of the way with a tie strap (or
equivalent).
NOTE
It is not necessary to disconnect the Reducing Agent
Injector lines, coolant lines, or unplug the electrical
connector. Remove the Reducing Agent Injector from
the Emissions Control Module with all lines and
connections attached, and secure it out of the way.
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
The Differential/Exhaust Pressure Sensor fasteners
and mounting bracket fastener/s must be removed
before removing the pressure sensor pipes.
•
Remove the bolt .
•
Loosen the clamps and remove the hoses
from the pipes.
•
Unclip the pipes and remove the Differential
Pressure Sensor -G505-, Exhaust Pressure
Sensor 1 -G450-, mounting bracket, and pipes as
an assembly.
•
Set the assembly aside in a clean, safe place.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 25 of 75
EGT and O2 Connector Locations:
•
Remove the connectors and free
up the wires from the retaining brackets and clips
for:
o
Exhaust Gas Temperature Sensor 4
-G648-. (Tan connector, sensor has
no bend)
o
Exhaust Gas Temperature Sensor 3
-G495-. (Brown connector, sensor
has 90 deg. bend)
o
Exhaust Gas Temperature Sensor 2
-G448-. (Black connector, sensor has
120 deg. bend)
o
Oxygen Sensor 1 before Catalytic
Converter -GX10- .
NOTE
EGT #4 -G648-, EGT #3 -G495-, and EGT #2 -G448may be located in any of the three available locations
shown, . Mark the locations at this time.
EGT #4: Tan connector, no bend in sensor
EGT #3: Brown connector, 90 deg. bend in sensor
EGT #2: Black connector, 120 deg. bend in sensor
EGT Orifice Locations on Emissions Control Module:
•
EGT #4: Tan connector, no bend in sensor
•
EGT #3: Brown connector, 90 deg. bend in
sensor
•
EGT #2: Black connector, 120 deg. bend in
sensor
NOTE
EGT #4 -G648-, EGT #3 -G495-, and EGT #2 -G448must be returned to their correct, corresponding
threaded orifice locations in the Emissions Control
Module as shown, or DTC’s regarding catalyst
efficiency and/or EGT Sensors will be set.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 26 of 75
•
Release the retainers in direction of ,
remove the NOx Sensor Control Module -J583 from the bracket and place on the engine.
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
•
Remove the following sensors from the
Emissions Control Module with a tool from the
-T10395A- and set the sensors aside in a clean,
safe place:
o
Oxygen Sensor 1 before Catalytic
Converter -GX10-
o
NOx Sensor -G295-
o
Exhaust Gas Temperature Sensor 2
-G448- . (Black connector,
sensor has 120 deg. bend
NOTE
It may difficult to remove the Exhaust Gas
Temperature Sensor 2 -G448- with the
turbocharger to Emissions Control Module clamp in
place. If necessary, remove the clamp at this time, or
the Exhaust Gas Temperature Sensor 2 -G448- may
also be removed just prior to Emissions Control
Module removal later in this procedure.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 27 of 75
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
•
Remove the Exhaust Gas Temperature Sensor 3
-G495- (Brown connector, sensor has a
90 degree bend) with a tool from the -T10395Aand set the sensor aside in a clean, safe place.
•
Open the coolant reservoir cap .
•
Turn the steering wheel to the straight ahead
position and remove the ignition key so that the
steering wheel lock engages.
Vehicles with “Keyless Access” Keyless Locking and
Starting System:
•
Switch the ignition off and open the driver door
so the steering wheel lock engages.
Continuation for all Vehicles:
•
Remove the bolts and remove the
footwell trim panel.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 28 of 75
Remove the bolt from the universal joint .
Then remove the universal joint in direction of
.
•
CAUTION
If the universal joint is separated from the
electromechanical steering gear, the following work
cannot be performed:
•
Ignition switched on.
•
Turning the steering gear.
• Turning the steering column.
These points must be observed, because otherwise it
can cause irreparable damage.
•
Raise the vehicle on hoist.
•
Remove the front wheels.
•
Remove the noise damping panel by
removing screws .
•
Pull noise insulation towards the rear and out of
front bumper cover in .
•
Disconnect the connector for the exhaust flap
.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 29 of 75
•
Remove the front exhaust pipe bolts .
•
Loosen the bolt and remove the clamp.
•
Remove the front exhaust pipe.
•
Remove the pendulum support bolts .
•
Remove the hex nut from the right and left
coupling rod .
•
Remove the coupling rod from the stabilizer
bar on the left and right sides.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 30 of 75
•
Mark the nuts for the ball joint to lower control
arms with a paint pin to reference the existing
alignment condition.
TIP
The current alignment condition can be documented by
marking the location of the nuts on the control
arm. By doing this and using the subframe locating pins,
it is not necessary to align the vehicle as a condition of
this repair. Vehicle alignments are not covered under
this action.
•
Remove the nuts on the left and right
side of the vehicle.
•
Remove the control arm from the ball joint.
•
Loosen the nut from the tie rod end, but do not
unscrew yet.
CAUTION
To protect the thread, screw the nut onto the pin a few
turns.
•
Remove the tie rod end from the wheel bearing
housing using the -T10187- and remove the
nut.
The repair 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. 2018 Audi of America, Inc. All Rights Reserved.
June 2018
23Y9 Page 31 of 75
•
Disconnect the connector for the Oil Level
Thermal Sensor -G266-.
•
If equipped, disconnect the connector from
the After-Run Coolant Pump -V51-. To do so,
open the catch in the direction of the
and release the connector.
•
Remove the clips for the wiring
harness from the subframe and the steering
gear.
The repair 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
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TSB/Document ID: Circular - Emiss
Replacement Service Bulletin Number:
MFR Communication Date: 2018-06-22
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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