2022-2023 Audi e-tron GT AC and Gearbox Issues TSB 91VT

Audi has released Technical Service Bulletin (TSB) 91VT, identified as a Customer Satisfaction Package (NVLW), for certain 2022-2023 Audi e-tron GT and RS e-tron GT vehicles. This proactive update aims to prevent several potential conditions related to the vehicle's air conditioning system, gearbox, and high-voltage charging capabilities. Owners of affected vehicles experiencing 2022 Audi e-tron GT AC issues or other related symptoms should contact their authorized Audi dealer.

Revision History

This TSB, 91VT, was originally published on September 4, 2024, as Revision 1.

Symptoms

Owners of affected 2022-2023 Audi e-tron GT and RS e-tron GT vehicles might experience one or more of the following issues:

• Air Conditioning Malfunction (Criteria K1): The air conditioning pressure temperature sensors may fail, leading to a non-functional air conditioning system. This is a common cause of 2022 Audi e-tron GT AC issues.
• Gearbox Lock Error (Criteria 01): After turning off the engine using the start/stop button, the gearbox lock might not reach its end position. This can prevent the lock from releasing and trigger a warning message on the instrument cluster stating, "gearbox error, max 120km/h, go to workshop."
• High-Voltage Charging Issues (Criteria 02 & 03): These issues manifest as an unauthorized display of the Turtle LED for a short period when the vehicle's high-voltage (HV) system is in the "not ready to drive" state. Owners might also observe the charging duration looping at less than 100%, or a charging abort indicated by a red LED, making fast charging impossible.

Technical Background

This update has been proactively issued by Audi to prevent the described conditions from occurring. The underlying causes vary depending on the specific criteria:

• Criteria K1: Relates to a certain production period where the air conditioning pressure temperature sensors (G395, G826, G827) may fail, directly impacting AC functionality.
• Criteria 01: Points to a potential issue with the gearbox lock mechanism, which can prevent proper engagement and disengagement.
• Criteria 02 & 03: Involve the convenience system control module and high-voltage battery control module, suggesting software-related anomalies affecting the HV system's readiness and charging processes.

Important Warnings for Owners

Audi has provided several critical warnings and instructions for technicians that are also important for owners to understand:

• No Consumer Notification: Audi is NOT notifying consumers directly about this Customer Satisfaction Package. Owners must proactively check with their authorized Audi dealer to determine if their vehicle is affected by TSB 91VT.
• Warranty Claim Requirements: The Software Version Management (SVM) process must be completed in its entirety so the database receives update confirmation. A warranty claim may not be reimbursed if there is no confirmation response to support the claim.
• Prior Service Action: Service Action 93P9 must be performed before completing the software update described in this TSB.
• No Unnecessary Replacements: Do not replace refrigerant pressure/temperature sensors if they have a green dot and were produced after calendar week 31 of 2021. Replacing them unnecessarily will not resolve the issue and may incur unwarranted costs.
• Software Update Risks: Performing software updates using Bluetooth or Wi-Fi connections increases the risk of losing connection and damaging control modules. Dealers are instructed to use a USB cable for the VAS Diagnostics Interface. Requests for additional time or parts will be denied if the GFF log shows the update was performed using Bluetooth or WiFi.
• Radiator Fan Hazard: During the update process, radiator fan(s) may cycle on at high speed. There is a serious risk that personal injury may result if contact is made with spinning fan blades. Keep hands and all objects away from the radiator fan(s) during the update process.
• Battery Charger Settings: Do NOT change any settings on the battery charger that could damage the charger or the vehicle. The battery charger must be restored to its original voltage value after the software update is completed.
• Software Update Failure: If the software update fails for any reason, ODIS feedback must be sent prior to further diagnosis. This ensures the failure/error is reported. Failure to do so may result in non-payment of consequential requests for additional time or parts.
• No TAC Case Creation: If an error message like "Configuration on control unit 0046 – convenience system central module could not be performed" appears during flashing, technicians are instructed to DO NOT create a TAC case as it is not required.
• No Wash/Loaner Claim: Dealers are instructed not to claim wash/loaner services under this action.
• Customer Notification: Dealers are required to inform customers in writing by recording all work performed, including updates, on the Repair Order.

Repair Procedure Summary

The repair process for TSB 91VT varies based on the specific criteria affecting the vehicle. It generally involves inspecting and potentially replacing sensors, followed by software updates.

Criteria K1: Air Conditioning Sensor Inspection and Replacement

For vehicles exhibiting 2022 Audi e-tron GT AC issues, technicians will inspect the G395, G826, and G827 refrigerant pressure/temperature sensors. This inspection does not require refrigerant recovery. The sensors are checked for a green dot. If a green dot is present on all three sensors, they do not require replacement. If any sensor lacks a green dot or was produced on or before calendar week 31 of 2021, it must be replaced. Replacement involves evacuating or draining the refrigerant, replacing the affected sensor(s) (part number 4M0-959-603-E), and then recharging the A/C system with R1234yf refrigerant.

Criteria 01, 02, and 03: Software Updates

For gearbox lock and high-voltage charging issues, a combined software update is performed. This procedure is critical and requires specific prerequisites:

1. Preparation: The ODIS software must be completely up to date. A battery charger, such as the VAS5908, must be connected to the vehicle battery and remain connected for the duration of the software update, ensuring battery voltage stays above 12.5 volts (or higher if directed by work instructions). The screen saver and power-saving settings on the diagnostic tester must be turned off to prevent interruptions. The VAS Diagnostic Tester (VAS6150X/VAS6160X) must be plugged in using its supplied power adapters and connected to the vehicle via a USB cable. Under no circumstances should the tester be used on battery power alone, or connected via Bluetooth or Wi-Fi, as this increases the risk of damage to control modules. All vehicle consumers (air conditioning, heater blower motor, lights, heated seats) must be switched off, and the selector lever moved to P.
2. Diagnostic Scan and Bus Sleep: Before the update, a full diagnostic scan must be performed using Guided Fault Finding (GFF), and the diagnostic protocol sent online. The diagnostic session should be saved for potential restoration. After the scan, a bus sleep procedure is performed for at least five minutes with the 12V charger disconnected. This involves disconnecting the 12V charger, removing the diagnostic interface, closing all doors, the hood, and the rear lid, then locking the vehicle and waiting for all interior lighting to turn off.
3. Software Flash: The software update is performed using the "Audi Flashing" process, not Guided Fault Finding (GFF). The communication path should be set to CAN. The charger must be set to a charging voltage of 14.8V, and the voltage shown in ODIS must be over 14V. The technician enters the appropriate SVM code: SWVGTA001 for criteria 01 and 02, or 91VTA396 for criteria 03, and follows the on-screen prompts. If the error message "High-voltage charging active - precondition not met" appears, the high-voltage system must be deactivated, the update performed again, and then reactivated.
4. Post-Update: After the software update, technicians must check the instrument cluster for any fault messages or warning lamps. Another bus sleep for at least five minutes with the 12V charger disconnected is required. If warnings related to the parking brake position persist, a parking brake calibration must be performed using the test plan "0003 – calibrate parking brake" within the guided functions for diagnostic address 0003. Finally, the diagnostic log must be sent to GFF Paperless, and the battery charger restored to its original voltage value.

Required Tools and Parts

Performing the 91VT update may require the following specialized tools and parts:

Special Tools

• Battery Tester/Charger: VAS5908 (or equivalent charger with a current rating of at least 90A)
• Diagnostic Tester: VAS6150X/VAS6160X (or equivalent)
• Socket - 24mm: T40284 (or equivalent)
• Engine Bung Set: VAS6122 (or equivalent)
• R1234yf Air Conditioning Service Unit: ROB1234YFX or VAS581005
• Removal Wedge: T40233 (or equivalent)
• Scraper Set: VAS6845
• Omega Clip Tool: T40280 (or equivalent)
• Puller - Windshield Wiper: T40394

Required Parts

• AC Pressure Sensor: Part Number 4M0-959-603-E (up to 3 sensors may be needed)
• Refrigerant Oil: Part Number G-052-535-M2 (up to 1.6 ml)
• R1234yf Refrigerant: Locally sourced (up to 98g for Canada, 3.46 oz for USA)

Warranty Information

This Customer Satisfaction Package is covered under warranty. Dealers must enter claims as soon as possible after completing the work. The service number for this action is 91VT, with a damage code of 0099 and parts vendor code 002.

Causal Indicators

• For vehicles not assigned criteria K1: Mark labor as causal.
• For vehicles assigned criteria K1: Mark labor as causal if all SENSORS are OK. Mark any SENSOR* as causal if any sensors are NOT OK.

Labor Operations

• 2706 89 50: Battery charge (SEE ELSA time units)
• 0151 00 40: Software update (100 time units, includes preliminary and follow-up work)
• 9310 83 00: Disable HV system voltage deactivate and activate (SEE ELSA time units)
• 0150 00 60: GFF/Guided functions (Time stated on diagnostic protocol)
• 4405 19 51: 1 Wheel remove+reinstall (SEE ELSA time units)
• 6644 19 50: Cowl panel trim remove+reinstall (SEE ELSA time units)
• 7007 19 50: Storage compartment remove+reinstall (SEE ELSA time units)
• 8709 01 99: Check 3 pressure sensors (15 time units)
• 8703 17 00: Refrigerant drain+fill (SEE ELSA time units)
• 8709 20 50: 3 Pressure switch remove+reinstall (SEE ELSA time units, use if all sensors replaced)
• 8709 19 50: Pressure switch remove+reinstall (SEE ELSA time units, if G395 replaced)
• 8709 19 51: Pressure switch remove+reinstall (SEE ELSA time units, if G826 replaced)
• 8709 19 52: Pressure switch remove+reinstall (SEE ELSA time units, if G827 replaced)

Additional labor operations for high-voltage system deactivation or parking brake calibration should only be added if required.

Owner Action

If you own a 2022-2023 Audi e-tron GT or RS e-tron GT and are experiencing any of the described symptoms, such as 2022 Audi e-tron GT AC issues, a "gearbox error, max 120km/h, go to workshop" warning, or charging problems, contact your authorized Audi dealer. Provide them with the TSB number 91VT so they can check your vehicle's eligibility and perform the necessary inspections and software updates. Since Audi is not directly notifying owners, it is crucial to proactively reach out to your dealer.

NHTSA Source: 91VT