Fuel Injectors, Unnecessary Replacement (GROUP 24, NO. 08-71)

Publication date: 2008-11-24
Reference number: GROUP 24, NO. 08-71
Supersedes refnos: 2010061, GROUP 24, NO. 05-01, GROUP 24, NO. 05-02

FUEL INJECTORS, UNNECESSARY REPLACEMENT

TECHNICAL SERVICE BULLETIN

Reference Number(s): GROUP 24, NO. 08-71 (2010061/4), Date of Issue: November 24, 2008

AUDI:	A4, A6, Cabriolet 2002 > 2005; S4, allroad 2002 > 2005; TT 2002 > 2005
GROUP:	24 - Multiport Fuel Injection

Superceded Bulletin(s): GROUP 24, NO. 05-02, Date of Issue: April 11, 2005

24 08 71 2010061/4 November 24, 2008. Supersedes Technical Service Bulletin Group 24 number 05-02 dated April 11, 2005.

APPLICABLE MODELS AND YEARS

Model(s)	Year	Eng. Code	Trans. Code	VIN Range From	VIN Range To
A4, A6, Cabriolet	2002 > 2005	AVK, BGN	N/A	N/A	N/A
S4, allroad	2002 > 2005	BHF	N/A	N/A	N/A
TT	2002 > 2005	BHE	N/A	N/A	N/A

Fuel Injectors, Unnecessary Replacement

Repair Manual or Guided Fault Finding (GFF) process leads you to the replacement of a fuel injector.

ENGINE INFORMATION

N/A

Prior to replacing a fuel injector, check the wiring pin connectors as described in the following work procedure:

Locate affected cylinder.
Swap ignition coil, spark plug or fuel injector from affected cylinder to another cylinder and observe if problem moves with the swapped component.

If problem moves with swapped component:

If problem remains at the same cylinder:

Check electrical connectors of fuel injectors as follows:
Disconnect connector of fuel injector(s).
Remove contact pins from the plug housing:

Fig 1: Contact Pins In Plug Housing
Push plug out of housing by releasing locking tabs -A-.

Fig 2: Locking Tabs
Remove secondary lock -B- upwards.

Fig 3: Secondary Lock

NOTE: Use appropriate tool from the VAS 1978 Wiring Repair Kit.
Push tool into slot -C- and remove female terminals from connector.

Fig 4: Slot -C- In Connector

With terminals removed from connector:

Push terminals (trial fit without housing) successively onto the appropriate male terminals of the injector.
Female terminals should fit snugly.

If the female terminals slide without resistance onto the appropriate injector:

Replace affected female terminals using the VAS 1978 wiring repair kit. See ETKA Special Catalogues for wires for connector housing 06A973722.
Tip: When repairing wiring, always follow instructions included in the VAS 1978 Wiring Repair Kit.

If the contact pins fit snugly to the pins:

The affected component needs to be checked using the VAS 5051 or VAS 5052 diagnostic tool and Guided fault finding.

WARRANTY INFORMATION

When procedure applies to vehicles within the New Vehicle Limited Warranty, use the following as necessary:
Claim Type	W2
Part Identifier	2440
Damage Code	2440 23 000 1
Labor Operation: Replace Terminals to Injectors	9709 41xx
xx = use appropriate labor operation and TU for the number of terminals repaired (see SRT).