Emissions Recall LZ - Reprogramming Of Engine Control Module And/Or Replacement Of Oxygen Sensors (CANADA) (LZ/LZ00 (CAN))

WARNING: This page is about the A6 Quattro, 2.7 D, Automatic, which is a different variant/trim than selected.

Publication date: 2004-02-01
Reference number: LZ/LZ00 (CAN)

EMISSIONS RECALL LZ - REPROGRAMMING OF ENGINE CONTROL MODULE AND/OR REPLACEMENT OF OXYGEN SENSORS (CANADA)

SERVICE CAMPAIGN BULLETIN

Reference Number(s): LZ/LZ00 (CAN) Revision #1, Date of Issue: February 2004

AUDI:

2003 Model Year A6 2.7L BiTurbo and A6 allroad 2.7L BiTurbo

Superceded Bulletin(s): LZ/LZ00 (CAN), Date of Issue: December 2003

IMPORTANT: Please Provide A Copy To All Personnel With Campaign-Related Responsibilities!

This supersedes the LZ circular dated December 2003.

SUBJECT

2003 Model Year Audi A6 2.7L BiTurbo and Audi A6 allroad 2.7L BiTurbo

Reprogramming of Engine Control Module and/or Replacement of One or Two Oxygen Sensors

This is to inform you of the initiation of an emissions recall involving some 2003 model year Audi A6 2.7L BiTurbo and Audi A6 allroad 2.7L BiTurbo gasoline engine vehicles.

PROBLEM DESCRIPTION

Audi has found that the oxygen sensor in the exhaust system could fail under certain conditions, potentially causing a vehicle to exceed Federal and/or California emissions standards, or to experience increased fuel consumption.

"Thermal shock" within the sensor caused by moisture accumulation could cause oxygen sensor failure. If the oxygen sensor fails, the vehicle's "check engine" light on the dashboard will illuminate.

REMEDIAL ACTION

Check the emission control system for proper function, reset electronically the engine's control module and replace one or two oxygen sensors, if necessary.

VEHICLE IDENTIFICATION NUMBER RANGE

The vehicles affected are within the following vehicle identification number ranges:

2003 Audi A6 2.7L BiTurbo

WAU LD _ 4B _ 3N 001 057 - WAU LD _ 4B _3N 116 107

2003 Audi A6 allroad 2.7L BiTurbo

WA1 YD _ 4B _ 3N 000 804 - WA1 YD _ 4B _3N 114 774

Please note that the above VINs represent the lowest and highest serial numbers of affected vehicles. Use of the OTIS View Campaign inquiry screen will allow you to determine whether or not a particular vehicle, within the above VIN ranges, requires the described work.

NOTE: Audi will not reimburse under this emission recall action any duplicate repair work or a repair outside the VIN ranges.

OWNER NOTIFICATION MAILING

Audi mailed first class notification letters to all known owners of affected vehicles on or about December 19, 2003. A copy of the owner letter is enclosed for your information.

VEHICLE ALLOCATION

Enclosed is a computer list containing the VINs including the owner names and addresses of vehicles that, according to our records, were sold by your dealership and require the LZ recall action to be performed.

PARTS INFORMATION

In some instances, this action may require replacement of 1 or 2 sensors. The part number for these sensors is 030 906 262 L. Until further notice, parts should be ordered only if the vehicle has a mil light on and DTCs related to the front oxygen sensor(s) indicate replacement is needed. Please contact your Campaign Parts Team Representative to place orders for vehicles, by VIN, which require the replacement.

WORK PROCEDURE

Objective: This procedure describes, "Update - Programming" (flashing) the engine control module (ECM) and, if necessary, replacing the front oxygen sensor(s) on 2003 Audi A6 and allroad vehicles with a 2.7 liter BiTurbo engines.

PARTS (IF NEEDED)

PARTS

Quantity	Part Number	Part Name
2	030 906 262 L	Oxygen Sensor, front

SPECIAL TOOLS AND EQUIPMENT

Diagnostic Tool VAS 5051 or VAS 5052 with the basic CD V.03.00 and the brand CD V.03.30 or higher are recommended. (Fig 1)

Fig 1: VAS 5051 And VAS 5052
VAS6017A K Lead Adaptor
Update Programming CD ROM Part No. AUDA6270104 (Fig 2)

Fig 2: Update Programming CD ROM

WORK SEQUENCE

CAUTION: THE FOLLOWING "UPDATE - PROGRAMMING" (FLASHING) PROCEDURE CAN REMOVE ANY ECM PROGRAMMING MODIFIED FOR PERFORMANCE.

A MODIFIED ECM IS ONE THAT HAS BEEN ALTERED FROM ITS ORIGINAL DESIGN AND NO LONGER MEETS THE SPECIFICATIONS AS APPROVED BY VOLKSWAGEN OF AMERICA INC.

VEHICLE OWNERS SHOULD BE NOTIFIED BEFORE RECALL WORK IS STARTED.

IMPORTANT:

Battery MUST have a minimum no-load voltage of 12.5V (failure to maintain 12.5V to 14.0V during the update programming can lead to an interruption in the process) (it is advised to use the IM 940 battery charger in the manual mode to maintain battery voltage).
VAS5051: connected to the vehicle and to 110V AC power supply at all times during the procedure.
VAS5052: connected to the vehicle with battery voltage requirements met and maintained.
Stored diagnostic trouble codes (DTCs) in any control unit must all be erased prior to starting the procedure.

CAUTION: The VAS 5051 or VAS 5052 must always be connected to an approved power supply at the approved voltages. Under no circumstance should the power supply be interrupted or should the diagnostic connector get disconnected during the updating procedure. Any appliances with high electromagnetic radiation (i.e. mobile telephones and cordless telephones) in and near the vehicle must be switched OFF.

Switch ignition to "ON" position.
Make certain all electrical consumers (lights, radio, etc.) are switched "Off".
Pull up lever to engage parking brake.
Connect VAS 5051 or VAS 5052 to the vehicle.
WARNING: DO NOT USE THE VAS 6017A ADAPTOR WHEN DOING THE UPDATE PROGRAMMING (FLASHING). CONTROL UNIT CAN BE DAMAGED. ADAPTOR IS FOR CHECKING CONTROL UNITS ONLY.
Connect power supplies as required.
Switch VAS 5051/5052 "ON" and insert "Update - Programming" CD into CD drive as soon as the start screen appears.
IMPORTANT: The CD ROM should be in the VAS 5051 or VAS 5052 when the scan tool is started up or, inserted when the start screen is showing. Check the light on the CD drive. It must not be flashing when going to the "Select Vehicle System" screen or the CD ROM will not be recognized.

NOTE: You must return to the start screen before starting a new "Update - Programming" session, otherwise the "Update - Programming" CD will not be recognized by the VAS 5051 or VAS 5052.
Select "Vehicle Self Diagnosis" mode -arrow-. (Fig 3)

Fig 3: VAS Display - Select "Vehicle Self Diagnosis"
Select vehicle system "01 - Engine electronics" -arrow-. (Fig 4)

Fig 4: VAS Display - Select Vehicle System

IMPORTANT: ECM part number and software level must be reviewed to determine if ECM requires updating.
Check ECM part number and software level on this screen or the ECM "Select Diagnosis Function" screen: (Fig 5)
- If part number is 4Z7907551S -arrow 1- and software level is 0020 -arrow 2-, no further work is required, exit self diagnosis and disconnect the VAS 5051 or VAS 5052.
- If part number is not 4Z7907551S with software level 0020, proceed to next step.
Select the > continue button -arrow-. (Fig 5)

Fig 5: VAS Display - ECM Part Number
The "Update - Programming" option -arrow 1- will appear whether the ECM requires updating or not whenever the Update - Programming CD ROM is installed in the diagnostic tool. (Fig 6)
Prior to flashing the ECM all DTCs MUST be erased.
IMPORTANT: Failure to erase ALL DTCs may cause the "Update - Programming" procedure to fail!
Select Diagnosis function 06 "End Output" -arrow 2-. (Fig 6)

Fig 6: VAS Display - Select Diagnosis Function
Select Diagnosis function "Collection services" -arrow-. (Fig 7)

Fig 7: VAS Display - Select Collection Services
Select "Check DTC memory - complete system" -arrow- which will interrogate all fault memories. (Fig 8)
IMPORTANT: If the vehicle has a mil light on, only DTCs related to the front oxygen sensor(s) are covered by this recall. Any other DTC checking, diagnosis or repairs are not part of or covered under this recall.

Fig 8: VAS Display - Select Check DTC Memory - Complete System

NOTE: If DTCs are found, print and erase all DTCs.
When function completed -arrow 1- comes up, select the < return button twice -arrow 2-. (Fig 9)

Fig 9: VAS Display - Function Completed
Select "01 - Engine electronics".
Select "Update - Programming" option at bottom of the screen -arrow-. (Fig 10)
CAUTION: ONCE "UPDATE - PROGRAMMING" FUNCTION HAS STARTED, SWITCHING THE IGNITION OFF OR DISCONNECTING THE DIAGNOSTIC CONNECTOR MAY COMPLETELY DESTROY THE ECM

Fig 10: VAS Display - Select Update - Programming
After selecting the "Update - Programming" function, the new program version 0020 is indicated along with the approximate amount of time to do the updating.
Select the > continue button -arrow- to start the programming. (Fig 11)

Fig 11: VAS Display - Select Continue Button To Start Programming

FLASH UPDATE IN PROGRESS

Please do not carry out any other work on vehicle at the same time! The "Update - Programming" process can be interrupted.

IMPORTANT: Do not turn on any electrical consumer that would cause a voltage drop.
This screen comes up and shows the percentage of progress for "Update - Programming". (Fig 12)

Fig 12: VAS Display - Programming In Progress
If during the "Update - Programming" this fault message is displayed: (Fig 13)
- Confirm that the VAS 5051 or VAS 5052 diagnostic tool power supply is adequate and that all appliances with high electromagnetic radiation (i.e. mobile telephones) are switched OFF.
- The "Update - Programming" process has stopped and is locked. Restart the process by selecting the "Repeat" button -arrow-. (Fig 13)
Fig 13: VAS Display - Fault Message
This screen comes up when the "Update - Programming" is complete. (Fig 14)
NOTE: The old software level is still displayed -arrows- The new software level is not displayed until the process is complete and the fault memories have been erased.

Fig 14: VAS Display - Programming Log
Select "Print" then select "Screen".
- The VAS 5051 will print to printer immediately.
- The VAS 5052 will hold the print until the process is complete and then you may take the tester to the printer for printing the screen.
Attach a copy of the print to the repair order.
Select the > continue button -arrow 2-. (Fig 14)
NOTE: Once the "Update - Programming" is complete, the control module must be re-initialized.
The tester requests you to switch the ignition OFF. (Fig 15)

Fig 15: VAS Display - Switch Off Ignition
Disconnect VAS 5051 or VAS5052 from the vehicle.
Connect VAS 6017A adaptor to the VAS 5051 or VAS 5052 and then to the vehicle.
After waiting 20 seconds, switch the ignition switch to the on position. (Fig 16)

Fig 16: VAS Display - Switch On Ignition

IMPORTANT: Wait at least 20 seconds before switching the ignition back to the "ON" position (failure to wait at least 20 seconds may damage the ECM).

NOTE: DTCs will be stored in various Control Modules during the "Update - Programming". All DTCs must be erased.
Select the > continue button -arrow- to erase all fault memories. (Fig 17)

Fig 17: VAS Display - Erase Fault Memory
When DTCs have been erased, this screen or a similar screen appears. (Fig 18)
Function ended appears near the bottom of the screen -arrow 1-. (Fig 18)
Select the < return button -arrow 2- to finish the updating. (Fig 18)

Fig 18: VAS Display - DTC Memory Erased
Updated software level 0020 and new control unit part number 4Z7907551S will be shown -arrow-. (Fig 19)

Fig 19: VAS Display - Software Level And Control Unit Part Number Shown

NOTE: The "Update Programming" selection will show on this screen although the updating has been completed whenever the "Update Programming" CD ROM is in the scan tool.
"Update - Programming " CD can now be removed from the VAS 5051/5052 diagnostic tool.
Print ECM screen to verify ECM update software level.
- The VAS 5051 will print to printer immediately.
- The VAS 5052 will hold the print until the process is complete and then you may take the tester to the printer for printing the screen.
Attach a copy of the prints to the repair order.
Select "Go To" then select "Exit".
If front oxygen sensor DTCs were present prior to the "Update - Programming" install new oxygen sensor as required.
Disconnect the VAS 5051 or VAS 5052, remove the VAS 6017A and use VAS 5051 or VAS 5052 and create engine readiness code.
NOTE: If the "Update - Programming" was interrupted and an error message appeared, or DTC 18089 P1681 is present in the ECM, the engine may not start. The "Update - Programming" procedure will need to be performed again. Please call the Audi Dealer Technician Helpline at 1 (800) 388-2834 for a contact number. The collection services step for DTC checking and clearing does not need to be repeated. Select "Update Programming" on the Selection Diagnosis Screen.
Work is completed.

TIME REQUIREMENTS/ REIMBURSEMENT

To ensure prompt and proper payment, be sure to enter, immediately upon completion of the repair work, the applicable reimbursement code listed below. Claims will only be paid for vehicles that show the LZ code in the OTIS View Campaign inquiry screen on the day of repair.

LZ DATA ENTRY PROCEDURE

Repair Code (Damage Code Field)	Time Units	Work Scope
LZ 11	10 T.U.	- Check. No reprogram necessary
LZ 12	140 T.U.	- Reprogram ECM and create engine readiness code
LZ 13	230 T.U.	- Reprogram ECM and create engine readiness code Install 1 front oxygen sensor 030 906 262L
LZ 14	250 T.U.	- Reprogram ECM and create engine readiness code Install 2 front oxygen sensors 030 906 262L
There is NO reimbursement for Vehicle Wash or Loaner Vehicle.

If the "Update - Programming" procedure was not successfully completed and needs to be performed a second time, an additional 25 T.U. for labor can be claimed by entering the dollar amount in the sublet labor field of the recall claim. A contact number from the Audi Dealer Technician Helpline must be included in the comments field.

The system automatically enters part number and/or labor applicable to the above listed codes.

For vehicle owners who could not be reached, according to your information, please enter into the system one of the codes indicated as applicable:

LZ 20 - Customer Refused Repairs
LZ 30 - Total Loss
LZ 40 - Vehicle Stolen
LZ 50 - Vehicle Exported

Fig 20: LZ Saga Claim Entry Procedure

ADDITIONAL CAMPAIGNS

Some of the affected vehicles may be involved in an additional corrective action. Please check your OTIS View Campaign inquiry screen so that any additional required work can be done simultaneously.

CAMPAIGN VERIFICATION

For verification, always check the OTIS View Campaign inquiry screen. The OTIS system is the only binding campaign inquiry and verification system; other systems are not valid and may result in non-payment of a claim.

DEALER OBLIGATION

To ensure a positive Audi experience, as well as minimize customers' inconvenience, dealers are urged to service each vehicle at the scheduled service appointment time. Every effort should be made to reduce any inconvenience to customers.

SERVICE HELP

If you have any questions regarding this or any other action, please contact us by calling (800) 741-2919.

DEALER PERSONNEL INFORMATION

Please inform and/or provide a copy of this communication to every person in your dealership who has campaign-related responsibilities, including parts and accounting personnel.

CUSTOMER LETTER EXAMPLE

Audi Canada

December 2003

Subject: Emissions Recall LZ - Reprogramming of Engine Control Module and/or Replacement of Malfunctioning Oxygen Sensor

Dear Audi Owner:

We are writing to inform you of a potential problem within the emission control system on some 2003 model year Audi A6 2.7L BiTurbo and Audi A6 allroad 2.7L BiTurbo vehicles. Our records show that you are the owner of one of these vehicles.

What Is The Problem?

Your vehicle is equipped with an oxygen sensor in the exhaust system that provides information to the engine control module. The information the sensor provides is needed to control the fuel and air mixture in the engine at precise levels. Audi and Environment Canada have found that this oxygen sensor could fail under certain conditions, potentially causing your vehicle to exceed emission standards, or to experience increased fuel consumption.

The oxygen sensor failure could be caused by "thermal shock" within the sensor caused by moisture accumulation.

Your vehicle is equipped with an onboard diagnostic system (OBD) that will warn you if certain emission-related failures occur in your car. The oxygen sensor is part of this system as well, and needs to operate correctly to allow the OBD system to do its job. If the oxygen sensor fails, the "check engine" light on your vehicle's dashboard will illuminate. If your vehicle has a "check engine" light on, contact your authorized Audi dealer as soon as possible, to arrange an appointment. However, do not wait for the light to come on before seeking service under this recall notice because the free service provided under this recall will prevent the type of oxygen sensor failure described above.

What Will Audi Do?

Your authorized Audi dealer will check your vehicle's emission control system for proper function, reset electronically the engine's control module and replace the oxygen sensor, if necessary.

What We Would Like You To Do

Please contact the Service Department of any authorized Audi dealer and schedule an appointment as soon as possible. The necessary work will take approximately one hour and will, of course, be free of charge.

If you are the lessor and registered owner of the vehicle identified in this action, please forward this information immediately by first class mail to the lessee.

Precautions

If the "check engine" light on your instrument panel comes on prior to the completion of this service, please contact your authorized Audi dealer immediately for scheduling the necessary repair.

Reimbursement of Expenses

If you have previously paid for reprogramming of the engine control module or the replacement of one or two oxygen sensors, the enclosed form explains how to request reimbursement. We would be pleased to review your reimbursement request. If you should have further questions, please feel free to call the Customer Relations Department at 1-800-822-2834.

We regret any inconvenience this matter may cause you, and thank you for your continued loyalty.

AUDI CUSTOMER CAMPAIGN REIMBURSEMENT CLAIM PROCEDURE

Please follow the instructions on the Claim form provided to file a claim for reimbursement. If you have any questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form.

Requests for reimbursement may include parts, labor, fees and taxes.
Reimbursement may be limited to the amount the repair would have cost if completed by an authorized Audi dealer.
Your claim will be acted upon within 60 days of receipt.
If your claim is approved, you will receive a check from Audi.
If your claim is denied, you will be contacted by Audi with the reason(s) for the denial.
If your claim is incomplete, you will be contacted by Audi identifying the documentation that is needed to complete the claim and offered the opportunity to resubmit the claim when the missing documentation is available.

Thank you for your continued loyalty.

Fig 21: Audi Customer Campaign Reimbursement Claim Form