2022-2023 Audi e-tron GT / RS e-tron GT HV Heater Service Action 82C9

Symptoms

Owners of 2022-2023 Audi e-tron GT and RS e-tron GT vehicles may experience a malfunction with the electric passenger compartment high-voltage heater. The primary symptom is that the vehicle interior will no longer be heated. This issue with the Audi e-tron GT HV heater is more likely to occur under specific conditions.

These conditions include frequent and prolonged use of the heater on its high setting. It is also more common if the vehicle battery is frequently charged at low ambient temperatures. Consequently, this problem is more prevalent in regions experiencing consistently cold environmental conditions.

Fault Codes / DTCs

If your Audi e-tron GT HV heater is malfunctioning, a technician may find one or more of the following diagnostic trouble codes (DTCs) stored in the vehicle's system:

Code	Description
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

Diagnosis for the Audi e-tron GT HV heater issue begins with checking for the specific DTCs listed above. If any of these fault codes are present, it indicates a problem with the high-voltage heater or its control module, necessitating further action.

The problem description highlights that the heater's failure is often linked to its operational patterns and environmental factors. Technicians will consider these conditions when diagnosing the issue. The repair procedure for Service Action 82C9 specifies that if any of these faults are present, the repair should proceed without further extensive diagnosis.

Important Warnings

Audi has issued several critical warnings regarding Service Action 82C9 that owners and dealerships must be aware of:

• Campaign Expiration: "This campaign expires on December 01, 2028. Work must be performed on or before this date to be eligible for payment. Keep this expiration date in mind when scheduling customers for this action. If a customer wishes to have this work performed after the expiration date, your dealership's normal costs associated with this work will apply."
• Dealer Inventory: "Dealers must ensure that every affected inventory vehicle has this campaign completed before delivery to consumers."
• High Voltage Safety: The document contains extensive safety warnings for technicians working on the high-voltage system. "Extremely dangerous due to high voltage. The high-voltage system is under heavy voltage. Severe bodily injury or death by electrocution or electric arcs is possible." Technicians are explicitly instructed to "Have a High-Voltage Technician or a High-Voltage Expert de-energize the high-voltage system." Other warnings include "Risk of injury - motor may start unexpectedly" and "Risk of damage to high-voltage wiring." These precautions underscore the serious nature of working with the high-voltage components, including the Audi e-tron GT HV heater.

Repair Procedure Summary

Service Action 82C9 involves a multi-step process to inspect and, if necessary, replace the Z189 high-voltage in-line heater. This procedure is complex and requires specialized tools and training.

1. Pre-Repair Verification: The technician first verifies the campaign status in the Audi Elsa system and checks for any previous repairs. It is crucial that all open safety recalls are completed before proceeding with this service action.

2. High-Voltage System De-energization: A critical safety step involves de-energizing the vehicle's high-voltage system. This is performed by a certified high-voltage technician using a 12V battery maintainer/charger and following specific test plans within the ODIS (Offboard Diagnostic Information System) and the ELSA repair manual. This ensures safety during work on the high-voltage Audi e-tron GT HV heater components.

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 cover, the front lock carrier cover, and the fender covers. The front luggage compartment lamp, emergency release button, and the front luggage compartment liner are also removed to provide clear access.

4. Z189 High-Voltage Heater Inspection: Once accessible, the Z189 high-voltage in-line heater is inspected. A key part of this inspection is checking the heater's production date. If the heater was manufactured before February 14, 2023, replacement is mandatory. If the production date is on or after February 14, 2023, the heater is considered acceptable, and the vehicle is reassembled without replacement.

5. Cooling System Drain (if replacement is required): If the heater needs replacement, the cooling system must be drained. This involves using ODIS to open the coolant valves and then carefully draining the system according to instructions in the ELSA repair manual. Technicians must take precautions against hot coolant and steam to prevent injury.

6. E-box Loosening: The under-hood E-box, which contains various electrical connections, is loosened and carefully moved aside. This step involves disconnecting specific connectors and releasing retaining clips to ensure adequate workspace.

7. Z189 High-Voltage In-Line Heater Replacement: The actual replacement of the Audi e-tron GT HV heater involves several precise steps. Electrical connectors and high-voltage cables are disconnected from the heater. Hose clamps are loosened, and coolant hoses are removed, with care taken to contain any residual coolant. The nuts and the potential equalization cable are removed, and the coolant expansion tank is moved aside to fully access the heater. The old Z189 heater and its bracket are then removed. The bracket is transferred to the new heater, which is then installed. New nuts are used and tightened to a specified torque of 8 Nm. Finally, the potential equalization cable is connected and tightened to 8 Nm.

8. Potential Equalization Measurement: After installation, a potential equalization measurement is performed using ODIS guided functions under the Thermal Management section. This ensures proper electrical grounding and safety.

9. Reassembly: All removed components are reassembled in the reverse order of removal. Specific torque values must be observed for various bolts, including luggage compartment liner bolts (8 Nm), lamp cover bolt (3 Nm), and wheel well liner/under body trim screws (2.5 Nm). Notably, the luggage compartment liner or underbody panels are not immediately installed to allow for leak checks.

10. Cooling System Fill and Bleed: The cooling system is refilled according to the ELSA repair manual, with ODIS used to control the coolant valves. The system is then bled to remove any air pockets, ensuring proper cooling and heating function.

11. High-Voltage System Re-energization: Once all work is completed and verified, a high-voltage technician re-energizes the HV system. This also follows specific test plans in ODIS and the ELSA repair manual, ensuring the system is brought back online safely.

12. Z189 Replacement Test Plan: A final specific test plan for Z189 replacement is performed in ODIS to confirm the successful completion of the repair.

13. Post-Repair Actions: The technician clears any fault memory from the vehicle's system and sends the repair log to GFF Paperless for documentation.

Required Tools and Parts

Performing Service Action 82C9 requires specialized tools and specific replacement parts:

Required Parts:

• HEATER: Part Number 9J1-963-507-F (also referred to as 9J1963507F)
• COOLANT Concentrate: Part Number G-12E-100-1G CON (also referred to as G-12E100S1)
• NUT: Part Number N-107-370-01 (also referred to as N-10737001)

Required Tools:

• Battery Tester/Charger: Capable of a minimum 90 Amp continuous supply.
• Diagnostic Tester: VAS6150X/6160X (or equivalent).
• Omega Clip Tool: T40280.
• Safety Gloves and Safety Goggles: Essential personal protective equipment.
• Padlock: T40262/1 (from Service Disconnect Lock -T40262-), used for securing the high-voltage system.
• Cooling System Service Machine: VAS531011.
• Hose Clamps: Up to 25mm (3094).
• Spring-Type Clip Pliers: VAS6891 (or equivalent).
• Removal Wedge: T40233.
• Scraper Set: VAS6845 (or equivalent).
• Warning Sign - "Do Not Switch On": VAS6650A, for safety during high-voltage work.
• Warning Sign - High Voltage: VAS6649, for safety during high-voltage work.
• Long 90° Pick Tool: Recommended for releasing E-box retaining tabs.

Owner Action

If you own a 2022-2023 Audi e-tron GT or RS e-tron GT, and suspect an issue with your Audi e-tron GT HV heater, or simply want to ensure your vehicle is covered, you should take the following steps:

• Contact Your Dealer: Schedule an appointment with an authorized Audi dealer as soon as possible to have Service Action 82C9 performed.
• Cost of Repair: The repair will be performed free of charge, provided it is completed before the campaign expiration date of December 01, 2028.
• Repair Duration: The work is estimated to take up to a full day to complete. Your dealer may require additional time for preparation or to accommodate their workshop schedule.
• Check Eligibility: You can verify if your specific vehicle is affected by this service action by visiting www.audiusa.com and using the Recall/Service Campaign Lookup tool with your Vehicle Identification Number (VIN).

---

Source: NHTSA ID: 11002186