Service
Description of concerns:1. Trunk lid doesn't fully close, reverses shortly before closing and opens again.
2. Trunk lid doesn't fully open / lifts up slightly, reverses and closes again.
3. Drive unit for automatic trunk lid operation sporadically (depending on the battery loading condition) fails to respond to the outside soft-touch switch [middle button on vehicle key or button in door trim panel or trunk lid trim (mainly when engine is OFF)]
4. Trunk lid hinge bent, lid adjustment no longer correct, lid protrudes over right side panel.
Tip:
Parts Information
Part numbers listed in this bulletin are for reference only. Always check with your Parts Dept. for the latest parts information.
Concern 1 may be caused by:
^ Trunk lid hinge stiff (corrosion in hinge joints).
^ Trunk lid adjustment incorrect.
^ Drop height not sufficient to operate the micro switch in trunk lid (clutch in drive is released too late, drop speed too low).
^ Wrong Gas-filled strut installed, power latching faulty.
^ Spring-loaded pins in stop buffers reducing drop speed.
(Refer to Service solution to Concerns 1 and 2)
Concern 2 may be caused by:
^ Trunk lid hinge is stiff (corrosion in the hinge joints).
^ Wrong Gas-filled strut installed.
^ Trunk lid drive unit does not provide enough torque for opening the trunk (particularly in subzero temperatures), solenoid clutch in the drive slips through.
(see Service solution below).
Concern 3 may be caused by:
^ The battery energy manager (BEM) which is on closed-circuit current stage 2 or higher (this prevents the comfort control unit from activating the drive unit).
(Refer to Service solution to Concern 3).
Concern 4 may be caused:
^ When opening/closing the trunk lid the customer has used his/her hand as well (adding too much pressure when opening or closing), but the external force recognition needs about 1 - 1.5 seconds to release the drive coupling. During this time the trunk lid/hinge may bend.
(Refer to Service solution to Concern 4).
Service solution to Concerns 1 and 2:
Tip:
To speed up the repair process, limit loaner expenses and save the customer time, please order and paint hinges prior to the scheduled appointment.
- After paint on hinges has cured, lubricate hinges at the hinge joints (arrows) with universal oil spray Part No. G 000 115 A2.
1. For all VINs:
- Interrogate DTC memory and complete any entries under 46 - central comfort system and 61 - energy manager (which may be the cause for problems with the automatic trunk lid).
2a. For Vehicles to VIN:4E_5N013028:
- If vehicle does not have new style hinges with appendix "F" from previous repair, install trunk lid hinges (with stainless steel hinge pins) Part No: 4E0 827 299 F (left) Part No: 4E0 827 300 F (right).
2b. For Vehicles from VIN 4E_5N013028 to VIN 4E_6N006915:
- Complete test steps 3 through 7.
3. For all VINs:
- Identify whether the correct Gas-filled struts are installed as follows:
- Left side, Part No. 4E0 827 551 B has one thick line (arrow) etched into the strut.
- Right side, Part No. 4E0 827 552 B has two thin lines (arrow) etched into the strut.
- If necessary install correct struts.
4. For all VINs:
- Check adjustment of trunk lid and hinges, adjust if necessary (see Repair Manual Body - Exterior, Group 55 - Hoods, lids, Trunk lid, adjusting).
Tip:
The electric drive only works if the trunk lid moves easily.
"Moves easily" is defined as; trunk lid moves freely if in manual mode and when closing, the following occurs:
- When trunk lid is opened at a distance of 8 cm to maximum 9 cm (3.1 to 3.6 in.) over the bumper and then released, the trunk lid freely drops into the lock.
- The lock fastens and the power latching locking bar (arrow) of trunk lid latch pulls the trunk lid the last 6 mm (trunk lid closed).
5. For all VINs:
- Check power latching mechanism & trunk lid lock.
^ When unlocked, locking bar (arrow) must be in upper position.
- Check by pressing locking bar (arrow) down.
- Fasten trunk lid lock (with trunk lid open) using a pin.
^ The power latching mechanism pulls down locking bar (arrow) by approx. 6 mm.
If there are deviations:
- Check the trunk lid lock and the power latching with Guided Fault Finding (GFF) and replace if necessary.
6. For vehicles to VIN 4E_5N016187:
- Engage lifting pins (arrow) in left/right stop buffers (located on left and right sides of trunk lid) by pressing them inwards and turning 90° to the left (pins will remain in).
7. For all VINs:
To ensure that the trunk lid opens and closes after replacing the hinges, activate the automatic trunk release as follows:
^ Test must be carried out after vehicle has been left at room temperature (15°C to 20°C)/(59°F to 68°F) for at least 4 hours.
^ The engine must be OFF.
^ Battery must have at least 12V (measured at battery terminals).
^ Check the automatic lift function by placing a container with 3ltrs. water / .79 Gal. (3 kg / 6.6 lb.) in the center of the trunk lid as shown.
- Place a soft cloth under the weight to prevent damage to trunk surface.
- While holding on to the weight, (hold so weight will not move but do not apply any downward pressure) press trunk release button (arrow).
If drive unit lifts trunk lid:
- Drive unit is OK. End test after trunk lid has risen by approx. 10 cm (4 in.) by pressing the button on outside of the trunk lid (this shows that the drive provides enough torque to open the trunk lid in cold conditions).
- Check if Drive unit closes trunk lid and locks from the fully open position.
If drive unit DOES NOT lift or close trunk lid, go to step 8.
8. Replace drive unit with Part No: 4E0 827 852E (w/software version 35S or higher) and repeat test.
If fault is fixed:
^ No further repairs are required.
If a concern still exists after these repairs are performed:
- It is mandatory to contact the Audi Helpline via Hotline channel (please advise in the Hotline channel that outlined instructions in the TB had been unsuccessful).
Service solution to concern 3:
1. Check DTC memory for Battery Energy Manager (BEM) for "rest current" DTCs.
2. Check DTC memory for any "closed-circuit current step 2 and - / or higher" (sporadically) DTCs.
If no DTCs are stored:
^ The DTCs may have occurred prior to 50 engine starts (after 50 engine starts, sporadic DTCs are erased automatically).
^ Also, with a BEM disconnection (step 2 or higher) the trunk light is also switched off.
^ Inform the Customer that this is an easy way to see if the battery voltage is too low).
- Inform the Customer about the function of the BEM as described in the Owner's manual under the chapter "Intelligent Technology Energy management and that he/she can recognize the disconnection with the help of the trunk light.
3. Read DTC memory of the Battery Energy Manager (BEM) and check any entries for references on "static current stage 2 or higher (sporadic)". (illustration is an example only).
If there are no entries:
^ The cut-off may have occurred prior to 50 engine starts (after 50 engine starts, sporadic DTCs are erased automatically).
If the BEM is switched OFF, the trunk lid open/close function is also OFF and the concern can be easily checked.
- Explain the BEM function to the Customer (as described in the Owner's Manual under Vehicle operation - "Intelligent technology - "Energy management") and that he can see by the trunk light whether the BEM is working.
Service solution to concern 4:
To avoid further damage:
- Explain to the customer (as described in the Owner's Manual under Controls and equipment - "Opening and closing - Automatic rear lid / Trunk lid operation" the following:
- That the automatic opening and closing must only be interrupted by pressing the buttons on the vehicle or on the remote key again.
- That if the automatic open/close feature has been interrupted, the lid must be opened or closed manually (like a mechanical trunk lid).
Tip:
^ Always observe the battery voltage. When the engine is on (high battery voltage) the trunk lid drive normally works correctly.
^ On 2004 through 2006 MY vehicles, the joints of the trunk lid hinges must be lubricated with universal oil Part No: G 000 115 A2 at every service (Maintenance tables will be changed to reflect this change).
Warranty:
If trunk lid replacement is required:
- It is mandatory to contact the Audi Helpline via Hotline channel (please attach pictures).