Inspection & Quality Control Flashcards

During a quality inspection, an Audi technician finds a stored fault code with 'implausible signal' for the steering angle sensor. What must be performed after clearing the code and verifying repair?

Answer: Perform a steering angle sensor calibration (basic setting) via ODIS

After any suspension, steering, or alignment work, the steering angle sensor must be recalibrated via ODIS so the ESP and driver assistance systems have an accurate zero-point reference.

An Audi paint inspection under a quality light reveals a small paint run near a rear door edge. At what stage of the repair process should this defect ideally have been caught?

Answer: During the wet-check inspection immediately after the base coat is applied

The wet-check inspection between base coat and clear coat application is the correct quality control gate for catching paint runs before they are locked in under clear coat.

When verifying torque specifications during an Audi wheel installation quality check, what is the correct tool and method?

Answer: Click-type or digital torque wrench set to the manufacturer's specified value in sequence

Audi specifies wheel fastener torque must be applied with a calibrated click-type or digital torque wrench to the published value to prevent over-torque, rotor distortion, or under-torque loosening.

A quality inspection on an Audi reveals the DSG (S tronic) transmission fluid is milky white. What does this indicate?

Answer: Coolant has entered the transmission, likely through a failed heat exchanger

A milky appearance in DSG fluid indicates coolant contamination, most commonly caused by a failed dual-clutch transmission oil/coolant heat exchanger, requiring immediate repair.

When inspecting Audi seat belt pretensioners during a post-collision quality check, which condition automatically requires replacement even if no deployment occurred?

Answer: The vehicle exceeded the g-force threshold recorded in the airbag control module's crash data

If the airbag module's crash data shows a g-force event above Audi's threshold, pretensioner replacement is mandatory even without visible deployment, as the pyrotechnic charge may be compromised.

During a final road-test quality check after a brake job on an Audi, the technician notices a pulsation at highway speed braking. What is the most likely root cause to investigate?

Answer: Excessive lateral runout or thickness variation in the new brake rotor

Brake pulsation at highway speed is typically caused by rotor lateral runout or disc thickness variation (DTV) causing cyclic pad deflection, which should be measured with a dial indicator.

An Audi B9 A4 comes in for a quality re-inspection after a front bumper replacement. The technician notices the front radar sensor for adaptive cruise control was repositioned. What must be done?

Answer: Perform a static or dynamic radar alignment calibration using ODIS and the required target fixtures

Any front radar sensor disturbed during bumper or body work must be recalibrated using ODIS and Audi-approved alignment targets to restore correct ACC and AEB system function.