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.
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 32 of 75
•
Place the Engine and Gearbox Jack -VAS6931 under the subframe.
•
To secure the subframe, the Locating Pins
-T10486/1- must be installed at the positions one after the other.
NOTE
The Locating Pins -T10486/1- may only be tightened to
a maximum of 20 Nm, since otherwise the locating pin
threads will be damaged.
•
Remove the bolts .
•
Remove the bolt and the support .
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 33 of 75
•
Insert the Locating Pin -T10486/1- and
tighten to 20 Nm.
•
Remove the bolts .
•
Remove the bolt and the support .
•
Insert the Locating Pin -T10486/1- into bolt
location and tighten to 20 Nm.
•
Remove the bolt .
•
Insert the Locating Pin -T10486/1- into bolt
location and tighten to 20 Nm.
•
Remove the bolt .
•
Insert the Locating Pin -T10486/1- into bolt
location and tighten to 20 Nm.
The subframe position is now secured.
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 34 of 75
•
Remove the expanding clip .
•
Lower the subframe using the Engine and
Gearbox Jack -VAS6931-.
•
Unclip the wiring harness from the steering
gear at the locations shown .
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 35 of 75
•
Disconnect the connectors from the
steering gear from underneath.
•
Secure the subframe to the Engine and Gearbox
Jack -VAS6931- with the accompanying strap.
•
Lift the clamp and remove the lower left
coolant hose from the radiator.
•
Allow the coolant to drain.
NOTE
The work instruction step for removal of the coolant
reservoir cap occurred earlier in this work instruction.
If it was not removed at that time, remove the coolant
reservoir cap before opening the clamp and removing
the hose.
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 36 of 75
•
Lift the clamp and remove the lower
right coolant hose from the charge air cooling
circuit radiator.
•
Allow the coolant to drain.
•
Loosen the hose clamp and remove the
lower coolant hose to the Heater Support Pump
-V488-.
•
Allow the coolant to drain.
•
Do not open the crankcase ventilation hose
connection . Only the other side of the hose
connection may be opened.
•
Free up the vacuum hose on the air guide pipe
.
•
Remove bolt and tilt the air guide pipe with
the intake tube backward and remove from the
turbocharger.
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 37 of 75
•
Remove the connector for the EGR
Temperature Sensor from the bracket,
disconnect it and free up the wire. It is not
necessary to remove the sensor from the EGR
cooler.
•
Remove the bolts .
•
Loosen the clamp and remove the air duct
pipe .
•
Remove the bolts and the resonator
.
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 38 of 75
•
Free up the wiring harness .
•
Remove the nut and bolts .
•
Loosen the hose clamps and remove
the coolant hoses.
•
Remove the left coolant pipes.
NOTE
Disconnect the coolant hoses at the cooler. It is not
necessary to remove each clamp, as the coolant tubes
can be removed as an assembly.
•
Loosen the clamp , remove the coolant hose
and drain the coolant.
•
Loosen the hose clamps and remove the
coolant hoses.
•
Remove the nut and bolt and remove
the rear coolant pipe.
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 4
-G648- (Tan connector, sensor has no
bend) with a tool from the -T10395A- and set the
sensor 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 39 of 75
•
Use the -T40207- to disconnect the connector
in illustration “A26-11266” (see next step).
Disconnect the securing pin on the connector
housing in direction of .
•
Push the heat shield boot aside, and disconnect
the connector using the -T40207-.
•
Loosen the clamp and remove the air guide
hose.
•
Loosen the clamp and remove the coolant
hose.
•
Loosen the bolt , remove the screw clamp,
and push the screw clamp towards the
particulate filter.
•
Remove the bolt using the -T10501-, and
loosen bolt .
•
Remove the EGR cooler.
•
Remove the bolt .
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 40 of 75
•
Place the -T10511- on the cylinder head cover
bolt heads and engage the retaining bracket
in the emissions control module
mounting strap.
•
If not previously removed, open the clamp
and position on the emissions control module
entrance funnel.
•
If not previously removed, remove the Exhaust
Gas Temperature Sensor 2 -G448- (Black
connector, sensor has 120 deg. bend) with a
tool from the -T10395A- and set the sensor aside
in a clean, safe place.
•
Remove the rest of the bolts in the order .
•
Pivot the lower emissions control module away
from the engine and push upward.
•
Pull the retainer out of the emission control
module bracket and remove emission control
module downward.
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 41 of 75
NOTE
The compensation element has an internal and external
thread. The external thread is a left-hand thread. The
internal thread is a right hand thread.
•
•
First, the compensation element is screwed into
place.
•
When the securing bolt is screwed into
compensation element, the compensation
element turns due to the friction on the tabs.
•
Because of the external left-hand thread, the
compensation element turns in the opposite
direction when the securing bolt is tightened.
•
This moves the compensating element up,
removing the play between exhaust purification
module and the engine.
Bring the retaining tabs as follows with the
-T10512/1-2- to the functional dimension.
o
Slide the compensation element
onto the -T10512/1-.
o
Insert the compensation element
into the -T10512/2-.
o
Bend back the retaining tabs by lightly
hitting the ball head with the
heel of the hand.
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 42 of 75
Installing:
Place the -T10511- on the engine.
•
NOTE
•
Pay attention that the -T10511- retaining
bracket is pivoted in the bulkhead direction
»open«.
•
Replace the seals, self -locking nuts, and
clamps when installing the new emissions
control module.
•
During installation, all cable ties for the heat
shields must be installed at the same location.
CAUTION
There is a risk of stress fractures and engine damage
due to the emissions control module being installed
under stress.
•
Before installing make sure that this
compensation element is not difficult to move
or fixed.
•
The compensation element must be easy to
turn on the threads.
•
Lubricant can only be applied on the threads.
The retainers must remain »clean«.
•
The bolt retaining tabs must be bent together
so far that the compensation element is taken
with when the bolt is turned.
•
Check the compensation elements for
ease of movement.
•
Remove the compensation element completely
clockwise (left threads).
•
Clean difficult to move threads and if necessary
coat with rust remover.
CAUTION
Compensation element connections cannot be coated
with every type of lubricant. Reducing the friction will
impair the function of the compensation element.
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 43 of 75
•
Install the new seal on the emissions control
module.
•
Remove the bolt for the clamp and lay the
clamp completely on the emissions control
module entrance funnel.
•
Do not bend the clamp.
•
Guide the emissions control module from below
in the installed position, push upward and
engage the bracket in the emissions control
module mounting strap.
•
The emissions control module now hangs
balanced in the approximate installation position.
NOTE
Replace all emissions control module bolts.
Emissions Control Module Tightening Sequence:
Step
Screw
Steps
1.
Screw-type
clamp
Position above the sealing
flange and install the bolt.
2.
Install hand tight and
immediately loosen 90°
3.
Screw-type
clamp
Tighten to 8 Nm
4.
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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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