2022-2023 Audi e-tron GT HV Heater Malfunction TSB 82C9

Symptoms of HV Heater Malfunction

Owners of affected 2022-2023 Audi e-tron GT and RS e-tron GT vehicles may experience a complete loss of heating in the vehicle's interior. This 2022-2023 Audi e-tron GT HV heater malfunction is more likely to occur if the heater is used frequently for extended periods on a high setting, or if the vehicle's battery is often charged in low ambient temperatures. This issue is particularly prevalent in cold climates. The waste heat scavenging heat pump, however, will continue to operate normally.

Fault Codes (DTCs)

If your vehicle's high-voltage heater is malfunctioning, a technician may find one or more of the following diagnostic trouble codes (DTCs) stored in the vehicle's system. These codes indicate issues related to the HV heater 2 control module or its circuits:

• B182C04: HV heater 2 control module faulty
• B182C29: HV heater 2 control module Range/Performance
• B182CF3: HV heater 2 control module High voltage power supply – error
• B182CF4: HV heater 2 control module High-voltage interlock, open circuit
• B182DF0: HV heater 2 Heater circuit 1 faulty

Diagnosis and Trigger Conditions

A technician will inspect the Z189 high-voltage in-line heater. The primary diagnostic step involves checking the production date of the Z189 heater. If the heater was produced BEFORE February 14, 2023, replacement is required. If the heater was produced ON or AFTER February 14, 2023, replacement is not necessary, and the existing heater is considered functional.

Repair Procedure Summary for Service Action 82C9

Audi Service Action 82C9 involves a detailed inspection and potential replacement of the high-voltage heater. The general procedure followed by technicians includes:

1. Initial Check: Verify the vehicle's VIN in the Elsa system to confirm eligibility and check for any other open service actions or recalls. All safety recalls must be completed before proceeding with this campaign.
2. High-Voltage System De-energization: This is a critical safety step. The high-voltage system must be safely de-energized by a high-voltage technician or expert to prevent severe injury or death from electrocution. This involves attaching a 12V battery maintainer/charger and following specific test plan steps in the ODIS diagnostic system to establish high-voltage de-energization.
3. Accessing the Heater: To reach the Z189 high-voltage in-line heater, several components must be carefully removed. This includes the front plenum chamber, front lock carrier cover, fender covers, the front luggage compartment lamp and emergency release button, and the front luggage compartment liner.
4. Heater Inspection: The Z189 high-voltage in-line heater is located and its production date is checked. As noted above, if the production date is before February 14, 2023, the heater requires replacement.
5. Heater Replacement (if necessary):
   • Cooling System Drain: The cooling system is drained according to ELSA repair manual procedures, taking precautions against scalding from hot coolant.
   • E-box Loosening: The under-hood E-box is loosened, and its connectors and wiring harness are disconnected to allow access.
   • Heater Removal: The old Z189 high-voltage in-line heater is carefully removed, along with its bracket.
   • New Heater Installation: A new Z189 high-voltage in-line heater (Part Number 9J1-963-507-F) is installed with its bracket, ensuring all nuts and screws are tightened to specified torque values.
   • Potential Equalization Measurement: The potential equalization cable is connected, and a measurement is performed using ODIS to confirm proper installation.
   • Cooling System Fill and Bleed: The cooling system is refilled with coolant concentrate (Part Number G-12E-100-1G CON or G 12E100S1) and bled to remove any air, following ELSA repair manual instructions.
6. Reassembly: All removed components are reinstalled in reverse order. Importantly, the luggage compartment liner and underbody panels are not installed until after the cooling system is filled and bled, allowing for leak checks.
7. High-Voltage System Re-energization: The high-voltage system is safely re-energized by a qualified technician.
8. Final Steps: Fault memory is cleared, and the campaign completion is logged.

Required Tools and Parts

To perform Service Action 82C9, technicians utilize specialized tools and specific parts:

• Heater: 9J1-963-507-F
• Coolant Concentrate: G-12E-100-1G CON or G 12E100S1
• Battery Tester/Charger: Capable of minimum 90 Amp continuous supply
• Diagnostic Tester: VAS6150X/6160X (or equivalent)
• Omega Clip Tool: T40280
• Padlock: T40262/1 (from Service Disconnect Lock -T40262-)
• Cooling System Service Machine: VAS531011
• Hose Clamps: Up To 25mm (3094)
• Spring-Type Clip Pliers: VAS6891
• Removal Wedge: T40233
• Scraper Set: VAS6845
• Warning Signs: "Do Not Switch On" (VAS6650A) and "High Voltage" (VAS6649)

Important Warnings for Owners

• Campaign Expiration: This service action is available free of charge only until December 01, 2028. If you wish to have this work performed after this date, your dealership's normal costs associated with this repair will apply.
• Pre-Delivery Requirement: Audi requires dealers to ensure that every affected inventory vehicle has this campaign completed before delivery to consumers.
• High-Voltage Safety: Due to the high-voltage components involved, this repair is extremely dangerous and must only be performed by trained high-voltage technicians at an authorized Audi dealership. Attempting this repair yourself could result in severe bodily injury or death.

Owner Action

If you own a 2022-2023 Audi e-tron GT or RS e-tron GT and experience a 2022-2023 Audi e-tron GT HV heater malfunction, or simply want to ensure your vehicle is checked, you should contact your authorized Audi dealer as soon as possible to schedule an appointment. Owner notifications will be sent in waves, starting in November 2023. The inspection and any necessary replacement of the high-voltage heater will be performed free of charge. You can also check your vehicle's eligibility for this or any other service campaign by visiting www.audiusa.com and using the Recall/Service Campaign Lookup tool with your Vehicle Identification Number (VIN).

NHTSA ID: 10244618