2021-2023 Audi e-tron Electric Drive Motor Leak TSB

Audi has issued Technical Service Bulletin (TSB) 93 24 22 2073858/2 to address an electric drive motor leak, identified by the diagnostic trouble code (DTC) P0AA600. This TSB, which supersedes previous bulletin 24-82 dated July 27, 2024, provides detailed instructions for diagnosing and repairing this issue in affected Audi e-tron vehicles.

This bulletin is crucial for owners experiencing a "Drive System/Electrical System Malfunction message" in their instrument cluster, as it outlines the proper diagnostic steps and repair procedures to resolve the underlying problem of an Audi e-tron motor leak.

Symptoms

Owners of affected Audi e-tron vehicles may observe the following symptoms:

• A "Drive System/Electrical System Malfunction message" appearing in the instrument cluster. This warning may not be continuously present during inspection.
• The specific message displayed on the dashboard is: "Electrical system: malfunction! Safely stop vehicle".

Fault Codes / DTCs

When diagnosing an Audi e-tron motor leak, technicians may find the following diagnostic trouble code (DTC) stored in the Battery manager control module -J840- (address word 008C):

• P0AA600: Hybrid/EV Battery Voltage System Isolation.

Diagnosis

Diagnosis for an Audi e-tron motor leak involves checking for internal coolant leaks within the electric drive motor. This can manifest as a full coolant drip container or coolant leaking from the active chamber on either the front or rear axle.

Technicians are advised to consult specific Audi technical training materials, such as the "SoST April 2023" document found in the Audi Knowledge Tank, to accurately localize the source of the leak. It's important to note that a few milliliters of coolant leakage from the resolver cover is not considered a technical issue, but no coolant should escape from the bores of the active chamber.

Important Warnings

• Vehicles should never be operated without a correctly filled cooling system. Ensure the coolant expansion tank seal is checked and re-secured after any work.
• The power electronics for electric drive must not necessarily be replaced if the electric drive motor is leaking. This applies even if corrosion or condensation is found on the high-voltage system connection for power and control electronics.
• If the power and control electronics for electric drive must be replaced as a group, this must be billed separately according to warranty accounting instructions.

Repair Procedure Summary

The repair process for an Audi e-tron motor leak involves a series of diagnostic and potential replacement steps, guided by TSB 93 24 22 2073858/2:

1. Leak Localization: Technicians will first check for and localize the source of the coolant leak in the electric drive motor, using specialized training materials.
2. Coolant Expansion Tank Check: The seal on the coolant expansion tank must be checked and re-secured.
3. Motor Inspection: The electric drive motor for both front and rear axles will be inspected for leaks. This includes checking the drip container for overflow or emptiness, indicating coolant leakage from the active chamber.
4. Component Replacement (if necessary): Depending on the diagnosis, the repair may involve replacing the front drive motor, rear drive motor, or both. For e-tron S models, two rear electric drive motors might need replacement.
5. Power Electronics Inspection: The power and control electronics for the electric drive will be inspected for corrosion or condensation. Crucially, these components should not be replaced unless absolutely necessary.
6. Power Electronics Replacement (if necessary): If replacement is unavoidable, the front or rear power and control electronics for the electric drive, or both for e-tron S models, will be replaced.
7. Diagnostic Protocol and Test Drives: A diagnostic protocol (GFF) will be performed, followed by test drives both before and after the service procedure to ensure the issue is resolved.

Required Tools or Parts

Technicians will need to consult ETKA (Electronic Parts Catalog) and ELSA (Electronic Service Information System) for specific part numbers and quantities. General parts that may be required include:

• Fasteners, bolts, nuts, and screws (as needed per repair manual).
• Front drive motor (quantity 01).
• Rear drive motor (quantity 01).
• Rear drive motors e-tron S (quantity 02).
• Front drive motor power electronics (quantity 01).
• Rear drive motor power electronics (quantity 01 or 02, depending on configuration).

Owner Action

If you own a 2021-2023 Audi e-tron or e-tron Sportback and experience a "Drive System/Electrical System Malfunction message" or suspect an Audi e-tron motor leak, it is recommended to contact an authorized Audi dealership. They will be able to diagnose the issue using TSB 93 24 22 2073858/2 and perform the necessary repairs. Warranty claims will be processed according to Audi's policies and procedures.

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Source: NHTSA ID: 11009974