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.
steps in the order written. Use care during
removal, reinstallation, and handling.
NOTE! Torque specifications have changed!
•
Install the Exhaust Gas Temperature Sensor 2
-G448- (Black connector, sensor has 120 deg.
bend), facing downward, dimension = 90
degrees and tighten to 60 Nm.
•
Install Oxygen Sensor 1 before Catalytic
Converter -GX10-, and NOx Sensor -G295- using
a tool from the -T10395A-. Tighten both sensors
to 52 Nm.
NOTE
It may difficult to install the Exhaust Gas Temperature
Sensor 2 -G448- with the turbocharger to
Emissions Control Module clamp in place. If the clamp
was not tightened in the previous steps, move the
clamp at this time. The Exhaust Gas Temperature
Sensor 2 -G448- may also have already been installed
prior to or after Emissions Control Module installation
earlier in this procedure. Tighten the clamp to 8 Nm.
•
Reconnect the connectors and secure the wires
into the retaining brackets and clips as previously
marked during removal for:
o
Oxygen Sensor 1 before Catalytic
Converter -GX10- .
o
Exhaust Gas Temperature Sensor 2
-G448-. (Black connector, sensor has
120 deg. bend)
o
Exhaust Gas Temperature Sensor 3
-G495-. (Brown connector, sensor
has 90 deg. bend)
o
Exhaust Gas Temperature Sensor 4
-G648-. (Tan connector, sensor has
no bend)
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 58 of 75
•
Insert the hoses into the Differential Pressure
Sensor Pipes and install new clamps onto
the hoses.
•
Install the bolt for the Differential Pressure
Sensor pipes and tighten to 8 Nm.
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
NOTE: Check the Exhaust Pressure Sensors and
Hoses for leaks before installing the heat shield boot.
•
Reinstall the Exhaust Pressure Sensor -G450and Differential Pressure Sensor -G505- in order
and tighten the bolts to 8 Nm.
•
Reconnect the connectors .
•
Reinstall and secure the heat shield boot .
NOTE
STOP!
Fragile Components. Follow these procedure
steps in the order written. Use care during
removal, reinstallation, and handling.
•
Reinstall the Reducing Agent Injector -N474- with
a new seal and a new clamp .
•
Secure the coolant line and the selective
catalytic reduction lines into the retaining
clips.
•
Reconnect the electrical connector .
•
Tighten the clamp to 5 Nm.
•
Reinstall the airbox, battery, battery tray, and
lower noise insulation. See Section D for
details.
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 59 of 75
Connect the VAS6150X Diagnostic Tester (or
equivalent) to the vehicle.
•
o
Start the ODIS program.
o
Perform the Guided Functions test plan
for “Filling Cooling System” to remove
any air bubbles trapped in the cooling
system.
o
Perform the Guided Functions test plan
“Replacing ECM or DPF” to reset the
DPF ash load levels (do not follow
instructions for replacing the ECM).
CAUTION
•
Failure to perform the “Filling Cooling System”
test plan may result in air bubbles trapped in the
cooling system. This condition may result in a
customer comeback or engine damage.
•
Failure to perform the “Replacing ECM or DPF”
test plan could result in pre-mature DPF/DOC
replacement.
Proceed to Section F to perform software update, if
required.
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 60 of 75
Section F – Software Update Procedure
NOTE
Prior to launching the VAS Diagnostic Tester and starting an update, ensure the following conditions are
met;
The ODIS software is completely up to date.
Refer to the “Alerts” section on ServiceNet home page for the current ODIS version.
The battery charger is connected to the vehicle battery and remains connected for the duration of
the software update.
•
Battery voltage must remain above 12.5 volts for the duration of the software update. Failure to
do so may cause the update to fail, which could result in damage to the control module. Control
modules damaged by insufficient voltage will not be covered.
The screen saver and power saving settings are off.
•
Failure to do so may result in the tester entering power save mode during the software update,
which could result in damage to the control module.
The VAS Diagnostic Tester is plugged in using the supplied power adapters.
•
Under no circumstances should the tester be used on battery power alone during the software
update. Failure to do so may result in the tester powering off during the update, which could
result in damage to the control module.
If using the Bluetooth VAS 5054A transmitter head, it is connected to the tester with a USB cable.
NOTE
Using Bluetooth for this action is PROHIBITED!
Damage caused to electronic components (e.g. ECM, TCM, etc.) during the SVM flash process is not covered.
•
Performing a software update using a Bluetooth connection increases the risk of losing
connection during the update, which could result in damage to the control module.
It also greatly increases the time required to perform the update. Requests for additional time
or parts will be denied if the GFF log shows the update was performed using Bluetooth.
The Bluetooth function of the scan tool is physically switched off .
VAS 6150 & VAS 6150A
(Front panel behind handle)
VAS 6150B
(Right side behind WIRELESS door)
VAS 6150C
(Left side behind SC/EX door)
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 61 of 75
WARNING
Radiator Fan(s) may cycle ON high speed during the Update Process! There is a serious risk that personal injury
may result if contact is made with spinning fan blades. Keep hands and all objects away from Radiator Fan(s) during
Update Process!
TIP
To Update-Programming using SVM, review and follow instructions in Technical Bulletin 2014603: Software Version
Management (SVM) Operating Instructions.
The SVM Process must be completed in its entirety so the database receives the update confirmation response. A
warranty claim may not be reimbursed if there is no confirmation response to support the claim.
Things to check before starting Software Version Management (SVM):
Verify your network connection through
LAN by checking the connection icon
(lower right of the home screen).
Check the icon within the ODIS
software that you have a connection.
Within the Connection Tab, verify that the
Connection type(s) display “Internet” .
Start a connections test and verify
that all connections pass.
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 62 of 75
•
At this time, refer to the “Alerts” section of ServiceNet
to verify that the most recent version of ODIS
Software is loaded to the VAS6150X Diagnostic
Tester (or equivalent). Failure to flash the vehicle
using the most recent version of ODIS Diagnostic
Software will cause faults in certain features of the
flash operation.
•
Failure to validate the ODIS Diagnostic version
before flashing the vehicle may result in flash failure,
and may delay if not negate the payment of the
emissions modification.
•
Switch the ignition on.
•
Apply the parking brake.
•
Switch the headlights off.
•
Connect the VAS6150X Diagnostic Tester (or
equivalent) to the vehicle.
•
Start the ODIS program.
•
Open the hood.
•
Open the battery cover.
•
Attach the GRX3000VAS Tester/Charger to the
vehicle battery.
TIP
Time to connect battery charger is included in the GFF
diagnostic protocol time units.
NOTE
STOP!
All TDI flashes MUST be completed during a single,
standalone ODIS Diagnostic Session. You MUST fully
complete this campaign and send all GFF Paperless logs
before beginning any other campaigns or operations.
You MUST also conclude any other campaigns or
operations that have been started and end the
corresponding diagnostic session and send all GFF
Paperless logs before beginning this operation. Failure
to independently separate the ODIS diagnostic session
for this campaign will cause problems updating the FAZIT
server in Germany and will delay if not negate the
payment of the emissions modification.
IMPORTANT!
If there are any ODIS “Hot-Fix” patches installed, they
MUST be removed from the scan tool before beginning
this operation. ODIS “Hot-Fix” patches may affect the
flash process.
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 63 of 75
•
Confirm that scan tool is communicating with the
diagnostic head by USB .
o
If the Bluetooth symbol is shown then disconnect the diagnostic head
from the vehicle and reconnect the USB
cable to the diagnostic head and then
reattach to the vehicle.
NOTE
KESSY Vehicles!
If loss of communication between the reader coil and
the key occurs during the flash, it may damage a
control module.
If equipped with a removable reader coil cap, it is
REQUIRED to remove the reader coil cap and insert
the key into the reader coil, or secure the key in close
proximity to the reader coil throughout the flash
process.
If the reader coil cap is not removable, it is REQUIRED
to secure the key to the steering column in close
proximity to the reader coil using a residue-free
adhesive or tape, an elastic cloth or stretch bandage,
or other improvised retaining device.
•
•
•
•
Upon ODIS startup, select “Diagnosis” .
•
Select “Self Test” .
•
Select “Software Version Management”, then select
“SVM Code input” .
•
Select “Attach to the test plan” .
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 64 of 75
NOTE
RISK of Scan Tool Damage!
Do not leave the scan tool on the windshield during the
flash process, as it is possible that the windshield wipers
may cycle.
•
From the Test plan screen, Select “SVM Code input”
test plan , then select “Perform test” .
•
Follow the on-screen prompts.
NOTE
Using Bluetooth for this action is PROHIBITED!
Damage caused to electronic components (e.g. ECM,
TCM, etc.) during the SVM flash process is not covered.
•
Enter the corrective action code (SVM code) as listed
below.
SVM code
23Y9A350
•
Follow the on-screen prompts until completion of the
flash operation.
NOTE
In the event of a Flash Malfunction!
In the event of a flash error or malfunction, STOP. DO
NOT exit the ODIS session, disconnect the scan tool,
attempt the flash again, or continue further in the test
plan.
Create an ATA ticket and allow the Audi Technicians
Helpline to provide direction with flash failures.
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 65 of 75
•
After the software update is completed and before
sending the GFF Log Online:
o
Select the “Control Module” tab.
o
Scroll down and right click on Address Word
0001/ Engine Control Module.
o
Select “Identify Control Module” .
At the end of the diagnostic session, Select “Send”
and follow the prompt for sending the log online.
•
NOTE
RISK of Non-payment!
•
Diagnosis logs must be sent on-line after the flash
process to be considered for reimbursement.
•
Verify that no other Campaigns or operations are
performed during this ODIS diagnostic session
before sending the log, and verify that the Engine
Control Module has been re-identified.
TIP
Technicians may find it helpful to also store the log on a
USB stick for back-up.
TIP
When exiting GFF, it is important to select “No”
.
•
Disconnect the VAS tester.
•
Switch off and disconnect the battery charger.
•
Reinstall the battery cover.
•
Release the parking brake.
•
Perform road test.
Proceed to Section E
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 66 of 75
Section E – Install/Inspect for Supplemental Vehicle Emissions Control Information Label
Install/Inspect for Supplemental Vehicle Emissions
Control Information Label
TIP
• Label must be installed on a painted surface
on the underside of the vehicle hood.
Note: Check the label part number before installing!
Match the label part number to your vehicle!
•
The surface where the label is to be installed
must be clean, dry, and free from oil residue
prior to installing the label.
•
Label must NOT cover any existing label(s).
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
- Formulated for engines with 75,000 miles or more, Valvoline...
- Delivers 20% better wear protection and 15% better sludge...
- Extra detergents safeguard against friction, corrosion and...
- Advanced friction-fighting additives help maximize...
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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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