Campaign - Replace Ignition Coils: Overview
November 2003Subject: 2001 2003 Model Year Audi Vehicles
Replace Ignition Coils
This is to inform you of the initiation of a service action campaign involving some 2001 through 2003 model year Audi vehicles. This service action pertains to the replacement of the ignition coils.
Problem Description
It is possible that if one of the vehicle's ignition coils fails, rough idling or reduced driving power could occur, in addition to illumination of the MIL light.
Remedial Action
Replace ignition coils in each affected vehicle.
Vehicle Identification and VIN Number Ranges
The vehicles affected by this action are identified as follows:
Owner Notification Mailing
Audi of America, Inc began notifying all known owners of this service action campaign by first class mail on June 6, 2003. Because a high number of vehicles are affected for most dealers, we have "staggered" the owner notification mailings, which continue on a weekly basis until all owners are notified.
Vehicle Allocation
Each dealer will receive a weekly computer printout listing containing VINs and owner information pertaining to owners of whom had been notified that specific week.
Parts Information
You will receive automatic weekly parts allocations based on each week's owner notification mailings to owners located within your area of responsibility. Do not place an order on your own until further notice.
NOTE:
All part numbers shown above are considered production level parts and do NOT need to be replaced.
Work Procedure
Objective:
This procedure describes changing ignition coils on 1.8 liter 2.7 liter & 3.0 liter engines in Audi TT, A4, and A6 vehicles.
Special Tools
- Puller T40039 - must be used to avoid damaging ignition coils during removal
Work Sequence:
Section A - 1.8 liter engine in Audi TT and A4 vehicles
Section B - 3.0 liter engine in Audi A4 and A6 vehicles
Section C - 2.7 liter bi-turbo engine in Audi A6 and Allroad vehicles
Section A - 1.8 Liter Engine in Audi TT and A4
IMPORTANT:
If the vehicle has a MIL light on, the diagnostic trouble codes (DTCs) must be checked. Only cylinder misfire DTCs related to ignition coil malfunction are covered by this service action. Any other checking, diagnosis or repairs are not covered under this service action.
- If applicable, connect VAS5051 and check DTCs
- Open hood and remove engine cover
- Check type of ignition coil
- If ignition coils -2- with part number (06B 905 115E), look like the illustration to the left and are bolted to the cylinder head with two bolts -3-, no further work is required. Reinstall engine cover and close hood
- If ignition coils are not bolted to the cylinder head, proceed to the next step
- Disconnect connectors -1- from ignition coils -2-
NOTE: Only ignition coils that are not at the latest production level must be replaced.
- Using Puller T40039, remove ignition coils
CAUTION: Use of tool T40039 is required to avoid damaging these sensitive components.
- Install new ignition coils (06B 905 115J/L) by pressing into cylinder head by hand only
IMPORTANT: Do not use any object to tap ignition coil into position. Do not twist ignition coil when installing.
- Reconnect connectors to ignition coils
- Reinstall engine cover and close hood
- If the MIL light was on and cylinder misfire DTCs were present, printed and erased, use VAS5051 and set engine readiness code
- Attach a copy of print out for diagnostic log (showing cylinder misfire DTCs) and readiness code "Test Complete" to repair order
NOTE: Readiness code setting is not related to this action when other components related to the MIL light are diagnosed and repaired.
- Destroy and properly dispose of removed ignition coils
Section B - 3.0 Liter Engine in Audi A4 and A6
IMPORTANT: If the vehicle has a MIL light on, the diagnostic trouble codes (DTCs) must be checked. Only cylinder misfire DTCs related to ignition coil malfunction are covered by this service action. Any other checking, diagnosis or repairs are not covered under this service action.
- If applicable, connect VAS5051 and check DTCs
- Open hood and remove cover -1- on left side of engine compartment
- Remove screw -arrow- securing coolant reservoir
- Raise coolant reservoir at front. Remove from rear bracket and move reservoir aside
- Remove cover -1- on right side of engine compartment
- Remove 2 screws -arrows-
- Remove air duct -1-
- Remove EVAP canister purge regulator valve -1- from holder on air cleaner
NOTE: Do not disconnect vacuum lines.
- Remove retainer -A-
- Remove wire harness -B- and fuel lines -E- from holders
- Disconnect secondary air hose -C-
- Unclip and remove mass air flow sensor -D-
- Remove air cleaner
- Remove harness screws -arrows- on left and right cylinder head
- Disconnect connectors -1- through -6- from ignition coils on left and right cylinder heads
NOTE: Only ignition coils that are not at the latest production level must be replaced.
- Using Puller T40039, remove ignition coils
CAUTION: Use of tool T40039 is required to avoid damaging these sensitive components.
- Install new ignition coils (06C 905 115E/F) by pressing into cylinder head by hand only
IMPORTANT: Do not use any object to tap ignition coil into position. Do not twist ignition coil when installing.
- Reconnect connectors to ignition coils
- Secure wire harnesses using previously removed screws
- Reinstall air cleaner
- Connect mass air flow sensor to air filter housing and close clips
- Insert fuel lines and wire harness into holders
- Reconnect secondary air hose
- Reinstall retainer for air cleaner
- Insert EVAP canister purge regulator valve into holder on air filter box
- Reinstall air duct and secure with 2 screws
- Reinstall cover over air filter housing
- Reposition coolant reservoir and secure with screw
- Reinstall cover on left side of engine compartment and close hood
- If the MIL light was on and cylinder misfire DTCs were present, printed and erased, use VAS5051 and set engine readiness code
- Attach a copy of print out for diagnostic log (showing cylinder misfire DTCs) and readiness code "Test Complete" to repair order
NOTE: Readiness code setting is not related to this action when other components related to the MIL light are diagnosed and repaired.
- Destroy and properly dispose of removed ignition coils
Section C - 2.7 Liter Bi-turbo Engine in Audi A6 and Allroad vehicles
Section C - Part 1 - Part Disassembly
IMPORTANT: If the vehicle has a MIL light on, the diagnostic trouble codes (DTCs) must be checked. Only cylinder misfire DTCs related to ignition coil malfunction are covered by this service action. Any other checking, diagnosis or repairs are not covered under this service action.
- If applicable, connect VAS5051 and check DTCs
- Open hood
- Release screws -arrows- and remove engine cover panels -A-, -B- and -C-
- Remove screws -1- and -2-
NOTE: On some vehicles, the screws -2- have been replaced with a retaining tab.
- Disconnect electrical connector from coolant level sensor and move coolant reservoir aside
NOTE: Do not disconnect coolant hose from reservoir.
- Remove oil filler cap
- Remove cover over left valve cover
- Check type of ignition coils
- If ignition coils -2- with part number (06B 905 115 E), look like the illustration to the left and are bolted to the cylinder head with two bolts -3-, no further work is required, reinstall cover over left valve cover, reinstall coolant reservoir, reinstall engine covers and close hood
- If ignition coils are not bolted to the cylinder head proceed to the next step
- Unclip tie wrap -3- from metal bracket
- Remove bolt -1- securing intake pipe
- Disconnect electrical connectors -1- from all ignition coils
- Remove cover -1- on right side of engine compartment
- Remove 2 screws -arrows-
- Remove air duct -1-
- Remove fuel lines from holders on air filter box
NOTE: Fuel lines do not need to be disconnected.
- Remove wire harness from clips on air filter
- Open clamps securing the mass air flow (MAF) sensor and remove it from the air filter
- Remove bolt -2- with washer and remove air filter
- Release screws -arrows- and remove cover panel over right valve cover
- Unclip tie wrap -3- from metal bracket
- Remove bolt -4- securing lower intake pipe
- Disconnect electrical connectors -1- from all ignition coils
- Proceed to Section C - Part 2
Section C - Part 2 - Ignition coil part number checking and replacement
- Check part number on top surface of each ignition coil
- If part numbers are 06B 905 115 J or L, ignition coils do not need to be changed. Proceed to Section C - Part 3
- If part numbers are not 06B 905 115 J or L, proceed to next step
NOTE: Only ignition coils that are not at the latest production level must be replaced.
- Use puller T40039 and remove only ignition coils that are not 06B 905 115J or L
CAUTION: Use of tool T 40039 is required to avoid damaging these sensitive components.
- Install new ignition coils (06C 905 115 L) by pressing into cylinder head by hand only
IMPORTANT: Do not use any object to tap ignition coil into position. Do not twist ignition coil when installing.
- Proceed to Section C - Part 3
Section C - Part 3 - Reassembly
- Reconnect connectors to all ignition coils
- Reposition right air intake pipe and secure with bolt -4-
- Clip tie wrap -3- to metal bracket
- Reinstall cover over valve cover
- Reinstall air filter and secure with bolt
- Insert MAF into air box and close clamps
- Reposition fuel lines into clips on air filter box
- Reposition wire harness into clips
- Reinstall air duct -1- and secure with screws -arrows-
- Reinstall cover over air filter
- Reposition left air intake pipe and secure with bolt -4-
- Clip tie wrap -3- to metal bracket
- Reinstall cover over left valve cover
- Reinstall oil filler cap
- Reconnect connector to coolant level sensor
- Reinstall coolant reservoir and secure with screw(s)
- Reinstall engine cover panels
- If the MIL was on and cylinder misfire DTCs were present, printed and erased, use the VAS 5051 and set engine readiness code
- Attach a copy of print out for diagnostic log (showing cylinder misfire DTCs) and readiness code "Test Complete" to the repair order
NOTE: Readiness code setting is not related to this action when other components related to the MIL are diagnosed and repaired.
- Destroy and properly dispose of removed ignition coils
Time Requirements/ Reimbursement
To ensure prompt reimbursement, be sure to enter, immediately upon replacement of the ignition coils the applicable reimbursement code listed below.
LS Data Entry Procedure