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.
Tighten to 20 Nm
5.
Install and turn until
compensation element
contacts. Do not tighten or turn
the bolt.
6.
Install and turn until
compensation element
contacts. Tighten the bolts to
20 Nm.
7.
Tighten to 20 Nm
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 44 of 75
•
Turn the compensation element (left-hand
thread) on the cylinder head using the
-3247- in the direction of until it contacts
the Emissions Control Module, then tighten an
additional 90°.
Tightening Sequence Continuation:
Step
Screw
Steps
8.
Turn until compensation
element contacts.
9.
Tighten to 20 Nm
10.
Additional 90° turn.
11.
An additional 45° turn
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 45 of 75
•
Install the hose on the EGR cooler .
•
Installed position: The marking “EGR side”
points to the EGR cooler.
•
Pay attention that the air duct hose sits free of
tension.
•
Install the EGR cooler with the seal and
clamp on the emissions control module.
•
Turn the EGR cooler counterclockwise
and at the same time insert the hose for the
turbocharger .
•
Move the screw-type clamp in its installation
position.
•
Follow the tightening sequence:
Step
Tightening Specification
1.
Position the bolts.
2.
Screw-type
clamp
7 Nm
3.
Install by hand all the way
4.
20 Nm
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 46 of 75
•
Reconnect the connector .
•
Reinstall the heat shield boot.
•
Reinstall the clamp on the air guide hose.
•
Reinstall the clamp on the coolant hose.
•
Reinstall coolant hose and install the clamps
.
•
Install the nut and bolt and tighten to 10
Nm.
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
•
Reinstall the Exhaust Gas Temperature Sensor 4
-G648- (Tan connector, sensor has no
bend) with a tool from the -T10395A- and tighten
to 60 Nm.
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 47 of 75
•
Reinstall the left coolant pipes.
•
Reinstall and secure the wiring harness .
•
Reinstall the nut and tighten to 10 Nm.
•
Reinstall the bolts and tighten to 8
Nm.
•
Reinstall the hose clamps .
TIP
Disconnecting upper radiator hose from the engine will
allow greater access for removal of the left side coolant
pipe.
•
Reinstall the resonator with new seal and
tighten the bolts to 8 Nm.
•
Reinstall the air duct pipe with new seal.
•
Reinstall the bolts and tighten to 8 Nm.
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 48 of 75
•
Reconnect the connector for the
EGR Temperature Sensor -G98- and secure the
wire to the retaining bracket.
•
Reinstall the crankcase ventilation hose .
Only the other side of the hose connection may
be opened.
•
Reinstall the vacuum hose onto the air guide pipe
.
•
Reinstall the air guide pipe and tighten screw to
8 Nm.
•
Reconnect the lower coolant hose to the Heater
Support Pump -V488- and install the hose clamp
.
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 49 of 75
•
Reconnect the right coolant hose onto the charge
air cooling circuit radiator.
•
Reconnect the clamp onto the lower left
radiator coolant hose.
•
Move the subframe attached to the Engine and
Gearbox Jack -VAS6931- into installation
position under the vehicle.
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 50 of 75
•
Replace the steering shaft seal .
•
Fold the seal over the collar of the steering
gear so that the rubber lip is seated properly
into the collar .
•
Check the seal for a secure fit.
•
Coat the seal from above with lubricant, for
example, soft soap.
•
Reconnect the electrical connectors
onto 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
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 51 of 75
•
Secure the wiring harness from the steering
gear at the locations shown .
•
Lift the subframe using the Engine and Gearbox
Jack -VAS6931- and route the electrical harness
into position.
•
Reattach 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 52 of 75
•
Remove the Locating Pins -T10486/1- one at a
time and install a new subframe bolt one after the
other.
•
Install the support bracket before installing
subframe bolts . Install new bolts in
location 2, 3, 4, and 5> and tighten to 20 Nm +
180 degrees.
•
Install and tighten the subframe bolts to 70 Nm + 180 degrees.
•
Remove the Engine and Gearbox Jack
-VAS6931- from under the subframe.
•
Reinstall the clips for the wiring
harness onto 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
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 53 of 75
•
Reconnect the connector for the Oil Level
Thermal Sensor -G266-.
•
Reconnect the connector from the After-Run
Coolant Pump -V51- and secure the catch .
•
Reinstall the tie rod ends on both side of the
vehicle and install new nuts. Tighten the nuts to
20 Nm + 90 degrees.
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 54 of 75
•
Install the ball joints into the control arms with
new nuts on the left and right side of
the vehicle.
TIP
To maintain original alignment, use the previously
marked location of the nuts to determine the
nut location settling point for the ball joint in the control
arms. Vehicle alignments are not covered under this
action.
•
Tighten the ball joint nuts to 40 Nm + 45 degrees.
•
Reinstall the front wheels. Check ELSA for VIN
specific wheel bolt tightening specification.
•
Install the coupling rods onto the stabilizer
bar on the left and right sides.
•
Install new nuts and tighten to 65 Nm.
•
Install new pendulum support bolts and
tighten to 50 Nm + 90 degrees.
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 55 of 75
•
Install the front exhaust pipe with a new seal and
clamp .
•
Tighten the front exhaust pipe bolts to 23
Nm.
•
Tighten the clamp to 7 Nm.
•
Reconnect the connector for the exhaust flap
.
•
Install clamping sleeve and tighten the clamp
to 30 Nm.
•
Install the universal joint onto the steering
shaft. Install a new bolt into the universal
joint .
•
Tighten the bolt to 20 Nm + 90 degrees.
•
Install the lower 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 56 of 75
•
Reinstall the coolant expansion tank and secure
the lines into the retaining clips.
•
Open the coolant reservoir cap .
•
Fill the cooling system using the Cooling System
Charge Kit -VAS6096/2-. Refer to ELSA for
details.
TIP
Filling the cooling system now will allow time to check
for and address any potential coolant leaks while you
install the remaining components onto the vehicle.
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
•
Install the Exhaust Gas Temperature Sensor 3
-G495- (Brown connector, sensor has 90
deg. bend) using a tool from the -T10395A- and
tighten to 45 Nm.
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 57 of 75
NOTE
STOP!
Fragile Components. Follow these procedure
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Last update on 2026-06-23 / Affiliate links / Images from Amazon Product Advertising API
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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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