2019-2024 Audi Starter-Alternator Emissions Action 27BQ

Audi has announced Emissions Service Action 27BQ, an emissions-related campaign to address a potential issue with the starter-alternator in various 2019-2024 Audi models. This service action aims to ensure vehicles continue to meet and exceed emissions expectations by resolving a condition that can affect the vehicle's start/stop functionality. The repair will be carried out by authorized Audi dealers at no cost to vehicle owners.

Document History

This Emissions Service Action 27BQ was originally published on April 30, 2024. It has undergone several revisions to incorporate additional vehicles, update parts, and refine work instructions. Key updates include:

• April 30, 2024: Original publication.
• May 03, 2024: Updated claiming instructions.
• June 11, 2024: Updated coolant claiming quantity.
• June 26, 2024: Updated parts sections, claiming, and work instructions.
• August 19, 2024: Updated affected vehicle chart, owner notification letters, parts, and claiming instructions to reflect the addition of 2021 model year vehicles.
• October 10, 2024: Updated affected vehicle chart, owner notification letters to reflect the addition of 2022 model year vehicles.
• October 24, 2024: Updated parts table.
• November 15, 2024: Updated affected vehicle chart and owner notification letters to reflect the addition of the next wave of vehicles.
• December 06, 2024: Updated affected vehicle chart, owner notification letters, parts, and claiming sections to reflect the addition of the final wave of vehicles. Also updated work instructions regarding battery charger connection before checking software version.
• December 17, 2024: Updated criteria in the parts section.
• January 07, 2025: Updated note in Section C work instructions.

Why This Matters

A defective starter-alternator can lead to inhibited start/stop functionality in affected Audi vehicles. While emissions are stated to remain within certification standards, this issue can result in increased CO2 and other emissions when the vehicle is stopped. Addressing this concern through Emissions Service Action 27BQ ensures your vehicle operates as intended and complies with environmental regulations.

Symptoms and Diagnosis

The primary symptom associated with a defective starter-alternator is the inhibition of the vehicle's start/stop functionality. While no specific dashboard warning lights or error messages are detailed in the service action, owners may notice that their vehicle's engine does not automatically shut off when stopped, or does not restart as smoothly as expected. The resolution of this Audi starter-alternator emissions issue begins with a diagnostic check.

Diagnosis for the Audi starter-alternator emissions issue involves a critical software version check. Technicians will connect a diagnostic tester and scan the vehicle using Guided Functions (GFF). They will specifically access the "Starter generator (00CC-Starter Generator)" module, identified as DA 00CC, to check its current software level. If the software level is found to be less than 0562, the starter-alternator will require replacement. If the software level is 0562 or greater, no replacement is necessary.

Critical Repair Procedure for Emissions Service Action 27BQ

The repair for the Audi starter-alternator emissions issue involves a multi-step process, beginning with an initial check and proceeding to a potential replacement of the starter-alternator if necessary. This work must be performed by authorized Audi technicians.

1. Initial Vehicle Check and Claim Entry

Before any work begins, technicians will check for a Campaign Completion label. If one is present, no further action is required. Otherwise, the vehicle's VIN is entered into the Elsa system to access the "Campaign/Action" screen. The technician must print this screen and keep a copy with the repair order. They must confirm the Campaign/Action status is "open"; if the status is closed, no further work is required. The Applicable Criteria ID is noted, as it guides the specific repair steps and parts needed. All available campaigns and actions must be performed in order of their start date, with the oldest performed first.

For claim entry, the service number is 27BQ, damage code is 0099, and parts vendor code is 002. The claim type is 7 10 for sold vehicles and 7 90 for unsold vehicles. The causal indicator is marked as causal if the Alternator (starter/generator) is OK, or "Alternator*" if the Alternator (starter/generator) is NOT OK. Technicians are instructed: "Do not claim wash/loaner under this action." The Criteria I.D. for this action is ALL.

2. Battery Charger Preparation

A crucial step before proceeding with diagnostics or repair is to prepare the battery charger. The VAS5908 battery charger must be switched off and then back on, ensuring its display has turned off before restarting. It must be operated in charging mode and set to a charging voltage of 14.8 Volt. An access code (6161) may be required, or DIAG+ mode can be activated by pressing and holding the select button if the charger has not been connected to the battery or has not been started. Technicians are warned: "DO NOT change any settings that will damage the charger or the vehicle." Furthermore, it is critical to avoid leaving the ignition on with insufficient charging voltage, as this could damage the 48V battery. After repairs, the battery charger must be restored to its original voltage value.

3. Starter/Generator Software Version Check

With the battery charger properly connected and set, the technician scans the vehicle using GFF. They will select DA 00CC, which corresponds to the starter-generator module. The software level of this module is then checked. If the software level is found to be less than 0562, the starter-alternator requires replacement. For example, a starter/generator with a software level of 0523 would require replacement. If the software level is 0562 or greater, replacement is not necessary, and the procedure moves to post-repair steps.

4. Starter/Generator Replacement (If Required)

If the software check indicates a replacement is needed, the technician will proceed with replacing the starter-alternator. Figure A27-10714 on page 25 of the service action document illustrates the starter-alternator assembly, identifying the starter/generator as component <15> and a stud as <18>. This component is heavy, so proper support is required during removal. The replacement procedure follows the detailed instructions in the ELSA repair manual under "Electrical System > Electrical Equipment > 27 Battery, Starter, Generator, Cruise Control > Generator > Generator, Removing and Installing." During this process, if the threads on stud <18> are damaged, the stud will not be reused and will be replaced with a bolt. After physical replacement, the technician performs the starter/generator replacement test plan via "DA 00CC > Guided functions > Replace control module" and follows all on-screen prompts.

5. Post-Repair Procedures

Once the campaign has been completed, the technician should stamp the repair order. Stamps are available for ordering through the Compliance Label Ordering Portal. A Campaign Completion Label, part number CAMP 010 000, is then filled out and affixed next to the vehicle's emission control information label. Care must be taken to ensure the new label "does not cover any existing label(s)."

Required Tools and Parts

Performing Emissions Service Action 27BQ requires specific tools and replacement parts:

Required Tools

• Battery Charger: VAS5908KIT (Max. 105Amp)
• Diagnostic Tester: VAS6150X/6160X (or equivalent)
• Cooling System Tester - Adapter: VAG1274/8, VAG1274/10
• Cooling System Charge Kit: VAS6096 (or equivalent)
• Hose Clip Pliers: VAS6362, VAS6340 (or equivalent)
• Belt Tensioner Locking Tool: T40098 (or equivalent)
• Socket - SW5 12 Points: VAS262023 (or equivalent)
• Torx Socket – T60: T40087 (or equivalent)
• Safety Gloves and Safety Goggles

Replacement Parts

The specific alternator part number varies based on the vehicle's criteria:

• Alternator:
  • 4N0-903-028-S (for SC, 24, 34, 44, 54 criteria)
  • 4N1-903-028 (for C8, A8, 4M, S8, 21, 22, 23, 25, 31, 32, 33, 35, 41, 42, 43, 45, 51, 52, 53, 55 criteria)
  • 4N1-903-028-B (for RQ, RS, 26, 27, 36, 37, 46, 47, 56, 57 criteria)
  • 4N0903028S (for SC or 24 or 34 or 44 or 54 criteria)

Other parts that may be required include:

• WASHER: N-900-970-01 (Qty. 1, for ALL criteria)
• BOLT:
  • N-910-718-01 (Qty. 2, for ALL criteria, replace only if original stud is damaged)
  • N-910-968-01 (Qty. 4, for S8, RQ, 25, 27, 35, 37, 45, 47, 55, 57 criteria)
  • N 91096801 (Qty. 4, Hexagon Socket Oval Head Bolt (Combi), for RQ, S8, RS criteria)
• GASKET:
  • 06M-121-488-A (Qty. 1, for C8, A8, 4M, SC, 21, 22, 23, 24, 31, 32, 33, 34, 41, 42, 43, 44, 51, 52, 53, 54 criteria)
  • 06M-133-237-A (Qty. 1, for C8, 21, 31, 41, 51 criteria)
• SEAL RING:
  • 4M0-145-117 (Qty. 1, for 4M, 23, 33, 43, 53 criteria)
  • N-910-191-01 (Qty. 1, for RS, 26, 36, 46, 56 criteria)
  • WHT-008-729-A (Qty. 1, for S8, RQ, RS, 25, 26, 27, 35, 36, 37, 45, 46, 47, 55, 56, 57 criteria)
  • N 90097001 (Qty. 1, for various criteria)
• SCREW, HEX. HD.: N 91071801 (Up to 2.00, if necessary)
• Coolant (G12 EVO Coolant): Approximately 3 liters of coolant are needed for the repair. Available in concentrate (G-12E-100-1G CON for US, G-12E-100-2G CON for Canada, G 12E100S1) and 50/50 pre-mix (G-12E-050-1G-RTU for US, G-12E-050-2G-RTU for Canada, G 12E050S0).

Important Warnings and Owner Information

Owners should be aware of several important points regarding this Emissions Service Action 27BQ:

• Inventory Vehicles: Dealers are explicitly instructed to ensure that every affected inventory vehicle has this campaign completed before delivery to consumers. This prevents new vehicle owners from receiving a vehicle that requires immediate service.
• California Emissions Compliance: For California owners, state regulations require that this emissions-related campaign be completed prior to vehicle registration renewal. Upon completion, your dealer will provide a signed "Vehicle Emission Recall - Proof of Correction" certificate (RC EMISCAVWAU) from their dealer. It is crucial to retain this certificate for your records. Owners are advised: "DO NOT MAIL THIS FORM to the DMV, unless requested."
• Lessor Responsibility: If you are a lessor and the registered owner of an identified vehicle, you must forward the service action letter to the lessee within ten days of receipt.
• Free Repair: The starter-alternator replacement, if required, will be performed free of charge to the owner.
• Dealer Time: While the work is estimated to take about half a day, dealers may need additional time for preparation and to accommodate their workshop schedule.
• Pre-existing Conditions: Diagnosis and repair of pre-existing conditions in the vehicle are not covered under this service action.
• Battery Charger Settings: Technicians are warned: "DO NOT change any settings that will damage the charger or the vehicle." Also, "If the ignition is left on with an insufficient charging voltage, damage to 48V battery may occur."

What Owners Should Do

If you own a 2019-2024 Audi model listed in the affected vehicles section, it is recommended to contact your authorized Audi dealer as soon as possible to schedule the necessary work for Emissions Service Action 27BQ. You can find a dealer and check your vehicle's eligibility for this or any other recall/service campaign by visiting www.audiusa.com (or www.audi.ca for Canadian owners) and using the Recall/Service Campaign Lookup tool with your Vehicle Identification Number (VIN). For any questions, you can contact Audi Customer Experience at 1-800-253-2834 (USA) or 1-800-822-2834 (Canada).

NHTSA ID: 11013704