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

Audi has released Technical Service Bulletin (TSB) 2073858/5 to address instances of electric drive motor coolant leaks in certain 2021-2023 Audi e-tron and e-tron Sportback vehicles. This TSB, which supersedes previous bulletin 93 24-29 dated November 7, 2024, provides updated service and warranty information for technicians.

Owners of affected vehicles may notice a specific warning message on their instrument cluster, indicating a potential issue with the drive system or electrical system. This TSB helps diagnose and resolve the underlying cause of this warning, particularly when related to an Audi e-tron P0AA600 leak.

Symptoms

Owners may observe a "Drive System/Electrical System Malfunction" message appearing in the instrument cluster. The specific verbatim message displayed is: "Electrical system: malfunction! Safely stop vehicle". This warning may not always be present during vehicle inspection at a service center.

Fault Codes / DTCs

When diagnosing this issue, technicians may find the following Diagnostic Trouble Code (DTC) stored:

• P0AA600: Stored in the Battery manager control module -J840- (address word 008C).

This DTC is a key indicator of the electric drive motor coolant leak that is the focus of this TSB.

Diagnosis / Trigger Conditions

This TSB applies when a Hybrid/EV Battery Voltage System Isolation issue is detected, or when an internal coolant leak has been identified in the electric drive motor during a workshop visit. An internal coolant leak is often evidenced by a full coolant drip container or coolant leaking from the active chamber on either the front or rear axle.

For the rear axle, an overflowing drip container suggests coolant is leaking from the active chamber. If the drip container is empty, coolant may still be leaking from the active chamber, especially in vehicles with low mileage. For the front axle, coolant leaking directly from the active chamber is the primary indicator. The Audi e-tron P0AA600 leak is specifically addressed by these diagnostic steps.

Important Warnings

Audi provides critical instructions for technicians and owners regarding this issue:

• "The power electronics must not be replaced if the electric drive motor is leaking." This prevents unnecessary part replacements.
• "A few milliliters of coolant leakage is not an issue from a technical perspective" when referring to the resolver cover. Minor seepage from this specific area does not indicate a problem.
• "Vehicles should never be operated without a correctly filled cooling system." Ensure the cooling system is properly maintained.

Repair Procedure Summary

The repair process outlined in TSB 2073858/5 involves checking for and localizing the source of the coolant leak. If an internal coolant leak in the electric drive motor is confirmed, technicians must first inspect the seal on the coolant expansion tank and re-secure it if necessary. The TSB details various labor operations depending on the location and severity of the leak, which may include:

• Checking the electric drive motor for leaks on both front and rear axles.
• Replacing the front or rear electric drive motor.
• Replacing both electric drive motors for e-tron S models.
• Replacing front or rear power and control electronics.
• Replacing both rear power and control electronics for e-tron S models.
• Procedures for deactivating and activating the high-voltage system, charging the battery, and performing test drives before and after service.

Owner Action

If you observe the "Electrical system: malfunction! Safely stop vehicle" warning message or suspect an Audi e-tron P0AA600 leak in your 2021-2023 Audi e-tron or e-tron Sportback, it is recommended to contact your authorized Audi dealership. They can perform the necessary diagnostics, including checking for DTC P0AA600, and carry out the appropriate repairs as per TSB 2073858/5. Warranty claims are subject to review by Audi Warranty policies and procedures.

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Source: NHTSA ID: 11012533