P0300

Factory Manual References

Factory service manual diagnostic procedure for 2012 audi a8

01 Mil On (DTC P0491/P0492 Secondary Air Injection System Bank 1/2 Insufficient Flow) (GROUP 01, NO. 17-10)

Publication date: 2017-04-20
Reference number: GROUP 01, NO. 17-10
Supersedes refnos: 2035002, 2035002/4, 2035002/5, GROUP 01, NO. 13-25, GROUP 01, NO. 15-46, GROUP 01, NO. 15-47, GROUP 01, NO. 16-55

01 MIL ON (DTC P0491/P0492 SECONDARY AIR INJECTION SYSTEM BANK 1/2 INSUFFICIENT FLOW)

01 MIL ON (DTC P0491/P0492 SECONDARY AIR INJECTION SYSTEM BANK 1/2 INSUFFICIENT FLOW)

TECHNICAL SERVICE BULLETIN

Reference Number(s): GROUP 01, NO. 17-10 (2035002/5), Date of Issue:  April 20, 2017
AUDI: A8 2010 - 2012
GROUP: 01 - On-Board Diagnostic
Superceded Bulletin(s): GROUP 01, NO. 16-55, Date of Issue:  March 14, 2016

APPLICABLE MODELS AND YEARS

01 17 10 2035002/5 April 20, 2017. Supersedes Technical Service Bulletin Group 01 number 16-55 dated March 14, 2016 for reasons listed below.

APPLICABLE MODELS AND YEARS

Model(s) Year VIN Range Vehicle-Specific Equipment
A8 2010 - 2012 All 4.2FSI

CONDITION

REVISION HISTORY

REVISION HISTORY
Revision Date Purpose
5 - Revised Required Parts and Tools  (Updated part number)
Revised Service  (Completely revised)
4 03/15/2017 Revised Required Parts and Tools  (Updated part number)
3 10/22/2015 Revised Production Solution  (Added solution)
Revised Service  (Completely revised)
Revised Warranty  (Updated TU for GFF)
Updated Required Parts and Tools  (Removed parts; updated part numbers)
  • MIL on.

The following DTCs are stored in the engine control module (ECM), J623 (address word 0001):

  • DTC P049100  (secondary air system bank 1, low flow)
  • DTC P049200  (secondary air system bank 2, low flow)

TECHNICAL BACKGROUND

The DTCs may appear during monitoring of the secondary air system during the engine cold starting phase. With the electric solenoid valves controlled, a diagnosis cycle is performed and the secondary air pressure is measured for a specified value.

The air pressure can be influenced by several factors within the secondary air system or the vacuum system.

PRODUCTION SOLUTION

Improved combination valves.

SERVICE

Check the vacuum system for leaks

During the catalyst heating phase, the secondary air valves could close too early if vacuum supply is low. Low vacuum supply can be a result of a leak in the vacuum system, so it is necessary to check the entire system for leaks.

  1. Check the vacuum check valve for leaks (Figure 1). The direction of flow should only be towards the intake manifold.

    If a leak is found at the check valve, replace the valve and recheck.

    G11336519
  2. With the hose to the check valve disconnected, apply 400 mmHG of vacuum with the VAS 6213 hand vacuum pump (Figure 2).

    If the vacuum supply drops during the first 10 minutes of the test, check the complete vacuum system and solenoid changeover valves for leaks using the diagram below.

    G11336520

    See diagram (Figure 3):

    1. Cylinder Bank 1 Intake Manifold Flap Vacuum Actuator
    2. Cylinder Bank 2 Intake Manifold Flap Vacuum Actuator
    3. Intake Manifold Runner Control Valve N316
    4. Left Secondary Air Injection (AIR) Combination Valve
    5. Right Secondary Air Injection (AIR) Combination Valve
    6. Cylinder Head Coolant Valve N489 - Vacuum Actuator
    7. Secondary Air Injection Solenoid Valves N112 and N320
    1. Vacuum from intake manifold
    2. Vacuum reservoir of cylinder head (0.9 l)
    3. Vacuum reservoir in inner valley of engine 0.7 l)
      G11336521

Repair as necessary.

  1. 4. If the engine warning light has come on in combination with DTC P049100 and/or DTC P049200, proceed as follows after the vacuum system was checked and with the procedure listed above.
  2. 5. Replace the following components:
    • Bank 1 and Bank 2 - Combination valves and gaskets (079 131 101 AN  and 06A 131 120 D  )
    • Secondary air injection sensor 1 (G-609) (06K 906 052  ). SAI solenoid valves N112 and N320 for combination valves (037 906 283 C  )
    • Delete the DTC entry before setting the readiness code.

    If the DTC is not logged after two engine starts, return the vehicle to the customer.

Check the exhaust catalyst

Only perform this section if the vehicle has a history of prior misfire or catalyst efficiency DTC.

Vehicles with misfire DTCs (e.g., P0300, P0301 - P0308, or P130A) or faulty catalyst DTCs (e.g., P042100 or P043100) in current or older diagnosis protocols may have faulty exhaust catalysts.

  1. Remove pre and post oxygen sensors and endoscope the catalysts from both ends and assess the honeycomb structure for damage.
  2. If damage is found, repair as necessary.

WARRANTY

WARRANTY INFORMATION

Claim Type: 
  • 110 up to 48 Months/50,000 Miles.
  • G10 for CPO Covered Vehicles - Verify Owner.
  • If vehicle is outside any warranty, this Technical Service Bulletin is informational only.
Service Number:  2640
Damage Code:  0010
Labor Operations:  Combi valves remove + reinstall (both) 2640 2019 40 TU
Secondary Air Solenoid Valves N112/N320 remove + reinstall both 2644 1999 40 TU
Pressure sensor G609 remove + reinstall 2675 1919 20 TU
Front heated oxygen sensors remove + reinstall both 2469 2019 130 TU
Rear oxygen sensors remove + reinstall both 2473 2019 90 TU
Borescope check of both exhaust catalysts 2640 0299 30 TU max
Vacuum system checks 2640 0299 30 TU max
Diagnostic Time:  GFF 0150 0000 Time stated on diagnostic protocol (50 TU max)
Road test prior to service procedure No allowance 0 TU
Road test after service procedure 0121 0004 10 TU
Technical diagnosis at dealer's discretion
(Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance details)
Claim Comment:  As per TSB #2035002/5

All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures Manual  . Claims are subject to review or audit by Audi Warranty.

REQUIRED PARTS AND TOOLS

PARTS INFORMATION

Part Number Part Description Quantity
06K 906 052 Secondary air injection sensor (G609) 1
06A 131 120 D Combination valves gaskets 2
079 131 101 AN Combination valves for secondary air system 2
037 906 283 C Solenoid valves N112/N320 for operating combination valves 2
TOOL INFORMATION

Tool Number Tool Description
VAS 6213 Hand Vacuum Pump
3337 Ring Spanner 7 piece set for oxygen sensor removal (if required).

ADDITIONAL INFORMATION

All parts and service references provided in this TSB (2035002) are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.

01 Mil On (DTC P0491/P0492 Secondary Air Injection System Bank 1/2 Insufficient Flow) (GROUP 01, NO. 17-10)

Publication date: 2017-04-20
Reference number: GROUP 01, NO. 17-10
Supersedes refnos: 2035002, 2035002/4, 2035002/5, GROUP 01, NO. 13-25, GROUP 01, NO. 15-46, GROUP 01, NO. 15-47, GROUP 01, NO. 16-55

01 MIL ON (DTC P0491/P0492 SECONDARY AIR INJECTION SYSTEM BANK 1/2 INSUFFICIENT FLOW)

01 MIL ON (DTC P0491/P0492 SECONDARY AIR INJECTION SYSTEM BANK 1/2 INSUFFICIENT FLOW)

TECHNICAL SERVICE BULLETIN

Reference Number(s): GROUP 01, NO. 17-10 (2035002/5), Date of Issue:  April 20, 2017
AUDI: A8 2010 - 2012
GROUP: 01 - On-Board Diagnostic
Superceded Bulletin(s): GROUP 01, NO. 16-55, Date of Issue:  March 14, 2016

APPLICABLE MODELS AND YEARS

01 17 10 2035002/5 April 20, 2017. Supersedes Technical Service Bulletin Group 01 number 16-55 dated March 14, 2016 for reasons listed below.

APPLICABLE MODELS AND YEARS

Model(s) Year VIN Range Vehicle-Specific Equipment
A8 2010 - 2012 All 4.2FSI

CONDITION

REVISION HISTORY

REVISION HISTORY
Revision Date Purpose
5 - Revised Required Parts and Tools  (Updated part number)
Revised Service  (Completely revised)
4 03/15/2017 Revised Required Parts and Tools  (Updated part number)
3 10/22/2015 Revised Production Solution  (Added solution)
Revised Service  (Completely revised)
Revised Warranty  (Updated TU for GFF)
Updated Required Parts and Tools  (Removed parts; updated part numbers)
  • MIL on.

The following DTCs are stored in the engine control module (ECM), J623 (address word 0001):

  • DTC P049100  (secondary air system bank 1, low flow)
  • DTC P049200  (secondary air system bank 2, low flow)

TECHNICAL BACKGROUND

The DTCs may appear during monitoring of the secondary air system during the engine cold starting phase. With the electric solenoid valves controlled, a diagnosis cycle is performed and the secondary air pressure is measured for a specified value.

The air pressure can be influenced by several factors within the secondary air system or the vacuum system.

PRODUCTION SOLUTION

Improved combination valves.

SERVICE

Check the vacuum system for leaks

During the catalyst heating phase, the secondary air valves could close too early if vacuum supply is low. Low vacuum supply can be a result of a leak in the vacuum system, so it is necessary to check the entire system for leaks.

  1. Check the vacuum check valve for leaks (Figure 1). The direction of flow should only be towards the intake manifold.

    If a leak is found at the check valve, replace the valve and recheck.

    G11336519
  2. With the hose to the check valve disconnected, apply 400 mmHG of vacuum with the VAS 6213 hand vacuum pump (Figure 2).

    If the vacuum supply drops during the first 10 minutes of the test, check the complete vacuum system and solenoid changeover valves for leaks using the diagram below.

    G11336520

    See diagram (Figure 3):

    1. Cylinder Bank 1 Intake Manifold Flap Vacuum Actuator
    2. Cylinder Bank 2 Intake Manifold Flap Vacuum Actuator
    3. Intake Manifold Runner Control Valve N316
    4. Left Secondary Air Injection (AIR) Combination Valve
    5. Right Secondary Air Injection (AIR) Combination Valve
    6. Cylinder Head Coolant Valve N489 - Vacuum Actuator
    7. Secondary Air Injection Solenoid Valves N112 and N320
    1. Vacuum from intake manifold
    2. Vacuum reservoir of cylinder head (0.9 l)
    3. Vacuum reservoir in inner valley of engine 0.7 l)
      G11336521

Repair as necessary.

  1. 4. If the engine warning light has come on in combination with DTC P049100 and/or DTC P049200, proceed as follows after the vacuum system was checked and with the procedure listed above.
  2. 5. Replace the following components:
    • Bank 1 and Bank 2 - Combination valves and gaskets (079 131 101 AN  and 06A 131 120 D  )
    • Secondary air injection sensor 1 (G-609) (06K 906 052  ). SAI solenoid valves N112 and N320 for combination valves (037 906 283 C  )
    • Delete the DTC entry before setting the readiness code.

    If the DTC is not logged after two engine starts, return the vehicle to the customer.

Check the exhaust catalyst

Only perform this section if the vehicle has a history of prior misfire or catalyst efficiency DTC.

Vehicles with misfire DTCs (e.g., P0300, P0301 - P0308, or P130A) or faulty catalyst DTCs (e.g., P042100 or P043100) in current or older diagnosis protocols may have faulty exhaust catalysts.

  1. Remove pre and post oxygen sensors and endoscope the catalysts from both ends and assess the honeycomb structure for damage.
  2. If damage is found, repair as necessary.

WARRANTY

WARRANTY INFORMATION

Claim Type: 
  • 110 up to 48 Months/50,000 Miles.
  • G10 for CPO Covered Vehicles - Verify Owner.
  • If vehicle is outside any warranty, this Technical Service Bulletin is informational only.
Service Number:  2640
Damage Code:  0010
Labor Operations:  Combi valves remove + reinstall (both) 2640 2019 40 TU
Secondary Air Solenoid Valves N112/N320 remove + reinstall both 2644 1999 40 TU
Pressure sensor G609 remove + reinstall 2675 1919 20 TU
Front heated oxygen sensors remove + reinstall both 2469 2019 130 TU
Rear oxygen sensors remove + reinstall both 2473 2019 90 TU
Borescope check of both exhaust catalysts 2640 0299 30 TU max
Vacuum system checks 2640 0299 30 TU max
Diagnostic Time:  GFF 0150 0000 Time stated on diagnostic protocol (50 TU max)
Road test prior to service procedure No allowance 0 TU
Road test after service procedure 0121 0004 10 TU
Technical diagnosis at dealer's discretion
(Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance details)
Claim Comment:  As per TSB #2035002/5

All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures Manual  . Claims are subject to review or audit by Audi Warranty.

REQUIRED PARTS AND TOOLS

PARTS INFORMATION

Part Number Part Description Quantity
06K 906 052 Secondary air injection sensor (G609) 1
06A 131 120 D Combination valves gaskets 2
079 131 101 AN Combination valves for secondary air system 2
037 906 283 C Solenoid valves N112/N320 for operating combination valves 2
TOOL INFORMATION

Tool Number Tool Description
VAS 6213 Hand Vacuum Pump
3337 Ring Spanner 7 piece set for oxygen sensor removal (if required).

ADDITIONAL INFORMATION

All parts and service references provided in this TSB (2035002) are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.

01 Mil On (DTC P0491/P0492 Secondary Air Injection System Bank 1/2 Insufficient Flow) (GROUP 01, NO. 17-10)

WARNING: This page is about the A8 Base, which is a different variant/trim than selected.
Publication date: 2017-04-20
Reference number: GROUP 01, NO. 17-10
Supersedes refnos: 2035002, 2035002/4, 2035002/5, GROUP 01, NO. 13-25, GROUP 01, NO. 15-46, GROUP 01, NO. 15-47, GROUP 01, NO. 16-55

01 MIL ON (DTC P0491/P0492 SECONDARY AIR INJECTION SYSTEM BANK 1/2 INSUFFICIENT FLOW)

01 MIL ON (DTC P0491/P0492 SECONDARY AIR INJECTION SYSTEM BANK 1/2 INSUFFICIENT FLOW)

TECHNICAL SERVICE BULLETIN

Reference Number(s): GROUP 01, NO. 17-10 (2035002/5), Date of Issue:  April 20, 2017
AUDI: A8 2010 - 2012
GROUP: 01 - On-Board Diagnostic
Superceded Bulletin(s): GROUP 01, NO. 16-55, Date of Issue:  March 14, 2016

APPLICABLE MODELS AND YEARS

01 17 10 2035002/5 April 20, 2017. Supersedes Technical Service Bulletin Group 01 number 16-55 dated March 14, 2016 for reasons listed below.

APPLICABLE MODELS AND YEARS

Model(s) Year VIN Range Vehicle-Specific Equipment
A8 2010 - 2012 All 4.2FSI

CONDITION

REVISION HISTORY

REVISION HISTORY
Revision Date Purpose
5 - Revised Required Parts and Tools  (Updated part number)
Revised Service  (Completely revised)
4 03/15/2017 Revised Required Parts and Tools  (Updated part number)
3 10/22/2015 Revised Production Solution  (Added solution)
Revised Service  (Completely revised)
Revised Warranty  (Updated TU for GFF)
Updated Required Parts and Tools  (Removed parts; updated part numbers)
  • MIL on.

The following DTCs are stored in the engine control module (ECM), J623 (address word 0001):

  • DTC P049100  (secondary air system bank 1, low flow)
  • DTC P049200  (secondary air system bank 2, low flow)

TECHNICAL BACKGROUND

The DTCs may appear during monitoring of the secondary air system during the engine cold starting phase. With the electric solenoid valves controlled, a diagnosis cycle is performed and the secondary air pressure is measured for a specified value.

The air pressure can be influenced by several factors within the secondary air system or the vacuum system.

PRODUCTION SOLUTION

Improved combination valves.

SERVICE

Check the vacuum system for leaks

During the catalyst heating phase, the secondary air valves could close too early if vacuum supply is low. Low vacuum supply can be a result of a leak in the vacuum system, so it is necessary to check the entire system for leaks.

  1. Check the vacuum check valve for leaks (Figure 1). The direction of flow should only be towards the intake manifold.

    If a leak is found at the check valve, replace the valve and recheck.

    G11336519
  2. With the hose to the check valve disconnected, apply 400 mmHG of vacuum with the VAS 6213 hand vacuum pump (Figure 2).

    If the vacuum supply drops during the first 10 minutes of the test, check the complete vacuum system and solenoid changeover valves for leaks using the diagram below.

    G11336520

    See diagram (Figure 3):

    1. Cylinder Bank 1 Intake Manifold Flap Vacuum Actuator
    2. Cylinder Bank 2 Intake Manifold Flap Vacuum Actuator
    3. Intake Manifold Runner Control Valve N316
    4. Left Secondary Air Injection (AIR) Combination Valve
    5. Right Secondary Air Injection (AIR) Combination Valve
    6. Cylinder Head Coolant Valve N489 - Vacuum Actuator
    7. Secondary Air Injection Solenoid Valves N112 and N320
    1. Vacuum from intake manifold
    2. Vacuum reservoir of cylinder head (0.9 l)
    3. Vacuum reservoir in inner valley of engine 0.7 l)
      G11336521

Repair as necessary.

  1. 4. If the engine warning light has come on in combination with DTC P049100 and/or DTC P049200, proceed as follows after the vacuum system was checked and with the procedure listed above.
  2. 5. Replace the following components:
    • Bank 1 and Bank 2 - Combination valves and gaskets (079 131 101 AN  and 06A 131 120 D  )
    • Secondary air injection sensor 1 (G-609) (06K 906 052  ). SAI solenoid valves N112 and N320 for combination valves (037 906 283 C  )
    • Delete the DTC entry before setting the readiness code.

    If the DTC is not logged after two engine starts, return the vehicle to the customer.

Check the exhaust catalyst

Only perform this section if the vehicle has a history of prior misfire or catalyst efficiency DTC.

Vehicles with misfire DTCs (e.g., P0300, P0301 - P0308, or P130A) or faulty catalyst DTCs (e.g., P042100 or P043100) in current or older diagnosis protocols may have faulty exhaust catalysts.

  1. Remove pre and post oxygen sensors and endoscope the catalysts from both ends and assess the honeycomb structure for damage.
  2. If damage is found, repair as necessary.

WARRANTY

WARRANTY INFORMATION

Claim Type: 
  • 110 up to 48 Months/50,000 Miles.
  • G10 for CPO Covered Vehicles - Verify Owner.
  • If vehicle is outside any warranty, this Technical Service Bulletin is informational only.
Service Number:  2640
Damage Code:  0010
Labor Operations:  Combi valves remove + reinstall (both) 2640 2019 40 TU
Secondary Air Solenoid Valves N112/N320 remove + reinstall both 2644 1999 40 TU
Pressure sensor G609 remove + reinstall 2675 1919 20 TU
Front heated oxygen sensors remove + reinstall both 2469 2019 130 TU
Rear oxygen sensors remove + reinstall both 2473 2019 90 TU
Borescope check of both exhaust catalysts 2640 0299 30 TU max
Vacuum system checks 2640 0299 30 TU max
Diagnostic Time:  GFF 0150 0000 Time stated on diagnostic protocol (50 TU max)
Road test prior to service procedure No allowance 0 TU
Road test after service procedure 0121 0004 10 TU
Technical diagnosis at dealer's discretion
(Refer to Section 2.2.1.2 and Audi Warranty Online for DADP allowance details)
Claim Comment:  As per TSB #2035002/5

All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures Manual  . Claims are subject to review or audit by Audi Warranty.

REQUIRED PARTS AND TOOLS

PARTS INFORMATION

Part Number Part Description Quantity
06K 906 052 Secondary air injection sensor (G609) 1
06A 131 120 D Combination valves gaskets 2
079 131 101 AN Combination valves for secondary air system 2
037 906 283 C Solenoid valves N112/N320 for operating combination valves 2
TOOL INFORMATION

Tool Number Tool Description
VAS 6213 Hand Vacuum Pump
3337 Ring Spanner 7 piece set for oxygen sensor removal (if required).

ADDITIONAL INFORMATION

All parts and service references provided in this TSB (2035002) are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.

Supporting Diagrams & Locations

Reference material from the factory manual for this diagnostic procedure.

Location

4.2L - MULTIPORT Fuel Injection - Engine Code: CDRA (1 Of 2)

Location

4.2L - MULTIPORT Fuel Injection - Engine Code: CDRA (2 Of 2)

Location

6.3L - MULTIPORT Fuel Injection - Engine Code(S): CEJA & CTNA

Location

87 GFF Test Plan Required For A/C Compressor Replacements Regardless Of Concern (GROUP 87, NO. 25-01)

Fuse/Relay

27 48V Reference: Charging 48V Battery With 12V Charger DTC P0A7D00/P0B2900 (GROUP 27, NO. 24-71)

Fuse/Relay

27 48V Reference: Charging 48V Battery With 12V Charger DTC P0A7D00/P0B2900 (GROUP 27, NO. 24-71)

Fuse/Relay

74 Damage Assessment Guidelines For Textile Seat Covers (GROUP 74, NO. 25-28)

Fuse/Relay

27 48V Reference: Charging 48V Battery With 12V Charger DTC P0A7D00/P0B2900 (GROUP 27, NO. 24-71)

Related Procedures

Procedure

57 AUDI Advanced Key Inoperative (GROUP 57, NO. 23-08)

Procedure

57 AUDI Advanced Key Inoperative (GROUP 57, NO. 23-08)

Procedure

57 AUDI Advanced Key Inoperative (GROUP 57, NO. 23-08)

Procedure

57 AUDI Advanced Key Inoperative (GROUP 57, NO. 23-08)

Procedure

57 AUDI Advanced Key Inoperative (GROUP 57, NO. 23-08)

Procedure

57 AUDI Advanced Key Inoperative (GROUP 57, NO. 23-08)

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