2022-2023 Audi e-tron GT High-Voltage Connector Cap Update

Audi has released Technical Service Bulletin (TSB) 93R5 to proactively address a potential issue in certain 2022-2023 Audi e-tron GT and RS e-tron GT vehicles. This update aims to prevent water intrusion into the high-voltage connector housing, which could occur due to a production irregularity. The TSB, identified as 93R5 UPDATE, outlines a procedure for retrofitting an Audi e-tron GT connector housing cap to safeguard the high-voltage system.

Why this update matters

A production irregularity in some Audi e-tron GT and RS e-tron GT vehicles manufactured within a specific period could allow water to enter the high-voltage connector housing. While no specific symptoms are currently noted, this proactive update, TSB 93R5, is crucial to prevent potential issues related to water intrusion into the vehicle's critical high-voltage electrical system. The installation of an Audi e-tron GT connector housing cap is designed to mitigate this risk, ensuring the long-term reliability and safety of the vehicle.

Eligibility and Verification

To determine if your 2022-2023 Audi e-tron GT is eligible for this update, an authorized Audi dealer must check the vehicle's status in the Elsa Campaign/Action Information system. The vehicle must show the 93R5 code as "open" on the day of repair. This procedure is only valid for vehicles within the New Vehicle Limited Warranty period.

Important Warnings for Owners

• Audi is not notifying consumers directly for this specific update. Owners must contact an authorized Audi dealer to check eligibility.
• "The Elsa system is the only binding inquiry and verification system; other systems are not valid and may result in non-payment of a claim."
• "All Safety Recalls must be completed prior to completing this campaign."
• If your vehicle is in dealer inventory, this procedure must be performed prior to sale.

Repair Procedure Summary

The repair outlined in Audi TSB 93R5 involves installing a new connector housing cap to protect the high-voltage connections. The procedure requires specialized tools and knowledge, and should only be performed by trained technicians at an authorized Audi dealership.

1. Access: The technician will begin by removing the front underbody panel of the vehicle. This step provides access to the high-voltage connector housing area.
2. Disassembly: Several bolts (identified as <1> through <8> in the technical diagrams) and the rear reinforcement (<9>) are then removed to further expose the area.
3. Cap Installation: A new connector housing cap is installed around the high-voltage battery connector housing. This cap consists of two parts: a rear cap (part number 4J3-971-921) and a front cap (part number 4J3-971-920). The rear cap is installed first, followed by the front cap, ensuring both halves are securely clipped together.
4. Reassembly: The rear reinforcement is reinstalled, with specific torque specifications for the bolts: <1> through <8> are tightened by hand initially, then <1> to 30 Nm, <2> to 55 Nm, and <3> through <8> to 30 Nm. Finally, the underbody panel is reinstalled, with its screws torqued to 2.5 Nm.

Required Parts

The following parts are required for the 93R5 UPDATE:

• CAP (front): Part Number 4J3-971-920
• CAP (rear): Part Number 4J3-971-921 These parts are managed under a "Free Order" system, and dealers receive an initial allocation.

Warranty Information

This update is covered under the vehicle's New Vehicle Limited Warranty. Dealers will submit claims using Service Number 93R5 and Damage Code 0099, with the causal indicator marked as "CAP (front)". The labor operations for this procedure include removing and installing the underbody panel, removing and installing reinforcement, and installing the connector housing caps. Dealers are instructed not to claim for vehicle wash/loaner services under this action.

NHTSA ID: 10236357