NHTSA ID Number: 10145638
Manufacturer Communication Number: A011879 2033001-
TSB/Document Date: 2018-10-15
Summary
This bulletin provides instructions on how to clean the secondary air ports if they have too much carbon and cause a restriction.
01 MIL on, DTC P0491 and P0492 stored at the same time in the ECM
01 18 79 2033001/15 July 12, 2018. Supersedes Technical Service Bulletin Group 01 number 17-32 dated
August 17, 2017 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A6
2009 - 2016
All
3.2 FSI AVS and 3.0 TFSI
A7
2013 - 2016
All
3.2 FSI AVS and 3.0 TFSI
S4
2010 - 2012
All
3.2 FSI AVS and 3.0 TFSI
Q7
2011 - 2016
All
3.2 FSI AVS and 3.0 TFSI
A5, S5
Cabriolet,
and Q5
2010 - 2016
All
3.2 FSI AVS and 3.0 TFSI
Condition
REVISION HISTORY
Revision
Date
Purpose
15
-
Revised title
Revised Required Parts and Tools (Clarification on gasket)
14
08/17/2017
Revised Required Parts and Tools (Added Power Steering Fluid)
13
08/16/2017
Revised Warranty (Updated table)
Customer states:
MIL on.
Workshop findings:
Both of the following DTCs are stored in the engine control module (ECM), J623 (address word 0001):
DTC P0491 (Secondary Air System Insufficient Flow, Bank 1).
DTC P0492 (Secondary Air System Insufficient Flow, Bank 2).
Mileage is greater than 15,000 miles.
Technical Background
Under certain driving conditions, the secondary air ports in the cylinder head can accumulate carbon over time,
causing a restriction.
Page 1 of 15
© 2018 Audi
of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Production Solution
Not applicable.
Service
Please note that before performing this repair for the first time, it is mandatory that the technician complete Audi
Academy Course #940134 and assessment #940134B. Otherwise, the warranty claim will be denied. The
course and assessment can be found on the Audi Academy CRC site. Specific video sections are referenced in
the instructions below.
Perform ODIS Testing – For all but A6 (C6) 3.2FSI and Q7 3.0T:
1. Delete all DTCs. Bring the engine to operating temperature.
2. Go to Control Modules >> 01 Engine Control Module >> Control module OBD>> Basic Settings >> Checking
Secondary Air System.
3. Select MVB: MASS_SA_REL[0] and MASS_SA_REL[1].
4. Perform test (Press brake and gas pedal at the same time, start test on ODIS tester).
5. While Basic Setting test is running, check if the secondary air pump runs normally (no unusual noises). In
addition, check for a leak in the secondary air hose routing between the pump and combi valves.
6. Immediately after the test is complete, read MASS_SA_REL[0] and MASS_SA_REL[1]. Depending on the
software level and engine code, the air mass flow will be displayed in one of two ways:
For old software version:
If the value is between 0.1 and 0.7, and there were no issues with the pump and hoses, the system needs
to be cleaned. Follow the instructions below.
For new software version:
If the value is between 13 and 16, and there were no issues with the pump and hoses, the system needs
to be cleaned. Follow the instructions below.
Perform ODIS Testing – For A6 (C6) 3.2FSI and Q7 3.0T only:
1. Go to Control Modules >> 01 Engine Control Module >> Control module OBD>> Basic Settings >> test 77.
2. While performing test 77, check if the secondary air pump is running and make sure it does not make any
abnormal or unusual noise:
Page 2 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
If test 77 fails but the pump is running and does not make any abnormal/unusual noise, perform the
cleaning process below.
If the pump is not running or if it makes abnormal/unusual noise, this TSB does not apply.
Tip: Always use the latest version of this TSB.
Prepare for Power Washing:
1. Move the exhaust sliding bushings
(that connect the catalytic converter
and muffler) back, then lower the
catalytic converter pipes (Figure 7).
For Q7, unbolt muffler from catalytic
converter. Cover mufflers with plastic
bag to prevent water from entering.
Cleaning water will drain out of the
catalytic converter pipes during the
cleaning process.
Figure 7. Lowered catalytic converter pipes.
2. Remove all spark plugs and cover the engine harness plugs for the coils (for water protection).
3. Drain the coolant so that it can be reused.
4. Bring front end of the car into service position (for Q5, A6, S4, and S5 Cabriolet) to make room in the front of
the engine. The Q7 has enough room for access to the front of the cylinder heads.
Page 3 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
5. For 3.0T only: remove the coolant
supply lines (intercooler of
supercharger) in the front of the
engine (Figure 8).
Figure 8. Front coolant pipes to be removed for 3.0T.
6. Remove the following components:
Coolant pipe (Figure 9, image 1).
Coolant flange (Figure 9, image
2).
Pulley and if needed bracket, of
power steering pump (Figure 9,
image 3).
Pulley of water pump (Figure 9,
image 4).
Coolant tube (Figure 9, image 5).
Dipstick tube (Figure 9, image 6).
Figure 9. Engine component removal.
Note:
When removing the dipstick tube, turn it 180 degrees, and then reinstall it for water protection.
Page 4 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Note:
To loosen the coolant tube, remove 2 bolts (Figure 10, image A and C), open
clip (Figure 10, image B), and pry bushing apart as shown in training video
(Figure 10, image D). There is no need to loosen the AC compressor.
Cover opening of right coolant pipe to prevent coolant circuit contamination.
Figure 10. Loosening the
coolant tube.
7. Remove main port freeze plug by
hitting the marked area with a small
punch until it turns (Figure 11).
Remove with pliers.
Figure 11. Marked area on main port of freeze plug.
Prepare to Power Wash:
Warning:
Read pressure washer user manual and follow these safety instructions.
Always insert special cleaning hose into adaptor and engine before turning pressure washer on.
If switching special cleaning to a different port, turn pressure washer off and release residual pressure by
pulling the trigger before removing the special cleaning hose from the engine.
Wear safety glasses and gloves.
1. Become familiar with the special tool set VAS6825 (Figure 12):
Page 5 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Special hose with scale for
cleaning single ports (Figure
12, image 1).
Special hose for cleaning
the main ports (Figure 12,
image 2).
6 Hose adaptor for the special
hose with scale (Figure 12,
image 3).
Engine adaptor for bank
one (Figure 12, image 4a).
Engine adaptor for bank two
(Figure 12, image 4b).
Figure 12. Special tool set VAS6825.
2. To catch water, put a pan under the front of the engine and under the disconnected catalytic converter pipes.
3. Install engine adaptors on the appropriate banks (Figure 13 and
Figure 14).
Figure 13. Engine adaptor on bank one.
Figure 14. Engine adaptor on bank two.
Page 6 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
4. To ensure proper pressure washer function, use a ¾-inch water supply hose (no longer than 60 feet) to
supply pressure washer.
The Audi-supplied pressure washer comes with a 22mm male-to-male adapter (to connect special tool to
trigger gun), a pressure gauge (to connect between pressure washer and high pressure hose), and a 220V
power adapter.
Make sure that pressure is at least 1800 psi when using the special single port cleaning hose (the hose with
the scale). Use the table below to compensate for low water pressure:
psi While Cleaning Single Ports
Cleaning Time in Minutes
Less than 1900
Pressure too low – check water supply
1900
4
2000 or higher
3
Power Wash the Ports
Cleaning Main Secondary Port:
1. Insert special main port cleaning hose (the hose without the scale) two inches into the engine adaptor.
2. Turn the pressure washer on.
3. Holding the cleaning hose tightly, pull the pressure washer trigger.
4. Gradually move the cleaning hose into the port, going back and forth until the combi valve is reached. All
water comes out at the adaptor #4.
5. Continue going back and forth through the whole port until only clean water drains out of the cylinder head.
6. Do the same with the other cylinder head.
Cleaning Single Ports:
1. Because every port has a different distance to the cylinder head, use the table below to position the hose
adaptor for the special single port cleaning hose (the hose with the scale) correctly into the hose. The back
side of the hose adaptor must align with the number on the scale of the cylinder to be cleaned (Figure 15).
The longitudinal slot on the hose adaptor must align with the black line on the scale for correct rotational
positioning (Figure 15).
Dimensions Port 1
2
3
Page 7 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Bank One
10.5
19.5
28.5
Bank Two
13.7
22.7
31.8
Figure 15: Arrow indicating how the back side of the adaptor must align with the scale. Red dotted line
indicating how the longitudinal slot must align with the black line on the scale.
2. After adjusting the position of the hose adaptor,
insert the special single port cleaning hose into the
hose adaptor, and bring it back into locking position
(Figure 16).
Figure 16. Locking position / transvers longitudinal
movement and of the hose adaptor
3. While cleaning, make sure that the pressure washer is supplying pressure greater than 1800 psi.
4. Based on the washer’s pressure, clean the port based on the table below. While cleaning, continuously move
the hose adaptor within the longitudinal and transvers slots (Figure 16).
Psi While Cleaning Single Ports
Cleaning Time in Minutes
Less than 1900
Pressure too low – check water supply
1900
4
2000 or more
3
Page 8 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Tip: After ten seconds of cleaning, all of the water should be draining out of the exhaust. If water is draining
out of the engine adaptor, check the position of the hose adaptor on the hose.
5.
Do the same for all remaining cylinders.
6.
It is recommended that after cleaning, all single ports
are checked with snap-on boroscope BK6000 (or
similar, with 90-degree lens), to make sure all ports
are clean (Figure 17).
Figure 17. Clean single port.
7.
When all carbon is removed, install a new main port plug using an 8mm socket with a short extension,
paying special attention to install it squarely. The outer edge of the plug should be recessed ~0.5mm – 1mm
behind the outer cylinder head edge.
8.
Reinstall all components (except spark plugs) and fill system with coolant according to ELSA.
9.
Using a vacuum extractor, remove all water from all combustion chambers.
10. Make sure all water is removed from the combustion chambers by using the self-start function twice
while the spark plugs are still removed (cover spark plug openings with a towel). Install spark plugs and
coils.
Make sure water is completely drained out of exhaust (make sure the exhaust is lowered enough).
Tip: There is no need to replace the engine oil; almost no water drains into the oil pan.
11. Allow the car to run at idle for 15 minutes to ensure that any remaining in the exhaust system evaporates.
After Power Washing:
1.
Delete all DTCs. Bring engine to operating temperature.
2.
Go to Control Modules >> 01 Engine Control Module >> Control module OBD >> Basic Settings >>
Checking Secondary Air System.
3.
Select MVB: MASS_SA_REL[0] and MASS_SA_REL[1].
Page 9 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
4.
Perform test (Press brake and gas pedal at the same time, start test on ODIS tester).
5.
Immediately after the test is complete, read MASS_SA_REL[0] and MASS_SA_REL[1].
For old software version:
If the value is between 0.9 and 1.0, the cleaning was successful.
For new software version:
If the value is between 0 and 5, the cleaning was successful.
Warranty
Claim Type:
1EB – Verify Vehicle Warranty Coverage
Service Number:
2644
Damage Code:
0010
Labor Operations:
Note:
Certain labor operations only apply if the vehicle is equipped with ACC. Only
claim those labor operations if applicable and if necessary.
Q5 CALB, CTUC, and CTUD engine (525):
Coolant pipe remove + reinstall
1961 1906
250 TU
Power steering pump remove + reinstall
(overlap reduced includes time for
exhaust and spark plugs)
4898 1999
60 TU
Loosen/fasten lock carrier
5038 0900
160 TU
Pressure wash
2644 1999
75 TU
Radar sensor adjust
9163 1550
30 TU
Preparation Driver Assist Calibration
9092 0051
30 TU
Vehicle front + rear measure
4495 0300
90 TU
Front wheel track adjust
4488 1550
20 TU
Rear wheel track adjust
4493 1550
20 TU
Front wheel camber adjust
4489 1550
40 TU
Page 10 of 15
© 2018 Audi of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of
America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the
publisher.
Rear wheel camber adjust
4494 1550
20 TU
Coolant pipe remove + reinstall
1961 1906
220 TU
Power steering pump remove + reinstall
(overlap reduced includes time for
exhaust and spark plugs)
4898 1999
60 TU
Loosen/fasten lock carrier
5038 0900
220 TU
Pressure wash
2644 1999
75 TU
Radar sensor adjust
9163 1550
30 TU
Preparation Driver Assist Calibration
9092 0051
30 TU
Vehicle front + rear measure
4495 0300
90 TU
Front wheel track adjust
4488 1550
20 TU
Rear wheel track adjust
4493 1550
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TSB/Document ID: A011879 2033001-
Replacement Service Bulletin Number:
MFR Communication Date: 2018-07-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
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