Technical Service Bulletin
01 V6 message during service reset: Secondary air injection system - checking secondary air mass
01 13 35 2035454/1 October 8, 2013.
Model(s)

Year

S4

2009 - 2011

A5

2010

S5 Cab

2010 - 2013

A6

2009 - 2011

Q5

2009 - 2012

Q7

2011 - 2012

VIN Range

Vehicle-Specific Equipment

All

3.2 FSI AVS and 3.0 TFSI

Condition
• During reset of the service reminder, the following message appears on the ODIS tester: “Secondary air
injection system - checking secondary air mass” (Figure 1).

Figure 1. Message on ODIS tester.
• MIL is not illuminated.

Technical Background
Under certain driving conditions, the secondary air ports in the cylinder head can accumulate carbon over time,
causing a restriction. The ODIS tester can identify the state of the restriction, and will request that the system is
cleaned in order to prevent the MIL from illuminating.

Production Solution
Not applicable.
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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.

Technical Service Bulletin
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 reference in the
instructions below.
Select the test plan in ODIS
1. In the ODIS tester (minimum ODIS 2.0.1 / 19.52), click on the “Secondary air injection system - checking
secondary air mass” message to follow the test plan (Figure 2).

Figure 2. Message on ODIS tester.
2. Select -1- for testing (Figure 3). No actual
test needs to be run; data is already stored
from last cold start in the ECM. This data
will determine the level of restriction.

Figure 3. Select -1- for testing.
3. Check the hosing between the secondary air pump and combi valves as instructed in the test plan.
4. Based on instruction from the tester (“clean immediately” or “clean within next 1000 miles” -- based on level of
restriction), clean the secondary air ports according to the instructions that follow in this bulletin.

Prepare for Power Washing

© 2013 Audi of America, Inc.

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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.

Technical Service Bulletin
1. Move the exhaust sliding bushings (that connect
the catalytic converter and muffler) back, then lower
the catalytic converter pipes (Figure 4).
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 4. 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 Cabrio) to make room in the front of the
engine. The Q7 has enough room for access to the front of the cylinder heads.
5. For 3.0T only: remove the coolant supply lines
(intercooler of supercharger) in the front of the
engine (Figure 5).

Figure 5. Front coolant pipes to be removed for 3.0T

© 2013 Audi of America, Inc.

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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.

Technical Service Bulletin
6. Remove the following components:
• Coolant pipe (Figure 6,1)
• Coolant flange (Figure 6,2)
• Pulley and, if needed, bracket of power steering
pump (Figure 6,3)
• Pulley of water pump (Figure 6,4)
• Coolant tube (Figure 6,5)
• Dipstick tube (Figure 6,6)

Figure 6. Engine component removal
Note:
When removing the dipstick tube, turn it 180 degrees, then reinstall it for water protection.
Note:
To loosen the coolant tube, remove 2 bolts (Figure
7, A and C), open clip (Figure 7, B), and pry bushing
apart as shown in training video (Figure 7, D). There
is no need to loosen the AC compressor.
Cover opening of right coolant pipe to prevent
coolant circuit contamination.

Figure 7. Loosening the coolant tube

© 2013 Audi of America, Inc.

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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.

Technical Service Bulletin
7. Remove main port freeze plug by hitting the
marked area with a small punch until it turns
(Figure 8). Remove with pliers.

Figure 8. 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 6):
• Special hose with scale for
cleaning single ports (Figure 9,1)
• Special hose for cleaning the
main ports (Figure 9,2)
• Hose adaptor for the special hose
with scale (Figure 9,3)
6

• Engine adaptor for bank one
(Figure 9, 4a)
• Engine adaptor for bank two
(Figure 9, 4b)

Figure 9. Special tool set VAS6825
2. To catch water, put a pan under the front of the engine and under the disconnected catalytic converter pipes.

© 2013 Audi of America, Inc.

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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.

Technical Service Bulletin
3. Install engine adaptors on the appropriate banks (Figure 10,
Figure 11).

Figure 10. Engine adaptor on bank one.

Figure 11. Engine adaptor on bank two.
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

© 2013 Audi of America, Inc.

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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.

Technical Service Bulletin
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 12). The
longitudinal slot on the hose adaptor must align with the black line on the scale for correct rotational
positioning (Figure 12).

Dimensions Port

1

2

3

Bank One

10.5

19.5

28.5

Bank Two

13.7

22.7

31.8

Figure 12: 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.

© 2013 Audi of America, Inc.

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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.

Technical Service Bulletin
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 13).

Figure 13. 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 13).

psi While Cleaning Single Ports

Cleaning Time in Minutes

Less than 1900

Pressure too low – check water supply

1900

4

2000 or more

3

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
14).

Figure 14. Clean single port.

© 2013 Audi of America, Inc.

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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.

Technical Service Bulletin
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