2022-2023 Audi e-tron GT Gearbox Error & AC Issues TSB

Audi has issued Technical Service Bulletin 91VT UPDATE, a Customer Satisfaction Package (NVLW), to proactively address several potential issues in 2022-2023 Audi e-tron GT and RS e-tron GT vehicles. This update aims to prevent problems related to the air conditioning system, gearbox locking mechanism, and high-voltage battery charging. Owners of affected vehicles may experience symptoms ranging from non-functional AC to critical warnings like "gearbox error, max 120km/h, go to workshop" or charging interruptions.

This bulletin, identified as 91VT UPDATE, outlines specific inspection and repair procedures to ensure the long-term reliability and performance of these electric vehicles. The update involves both hardware inspection and replacement for certain components, as well as critical software updates for various control modules.

Symptoms

Owners of 2022-2023 Audi e-tron GT and RS e-tron GT vehicles may encounter several issues that this TSB aims to prevent. One common problem involves the air conditioning system, where pressure and temperature sensors (G395, G826, G827) may fail, leading to the air conditioning not working at all. This can significantly impact cabin comfort.

Another critical symptom relates to the gearbox. After turning off the engine by pushing the start/stop button, the gearbox lock might not engage or release correctly. This can result in a warning message appearing in the instrument cluster, stating, "gearbox error, max 120km/h, go to workshop." If you see an Audi RS e-tron GT gearbox error, this update is likely relevant to your vehicle.

Furthermore, the bulletin addresses potential charging issues. These include an unauthorized display of the "Turtle LED" for a short period when the high-voltage (HV) system is in a "not ready to drive" state. Owners might also experience charging duration loops that stay below 100% or complete charging aborts indicated by a red LED, making fast charging impossible.

Important Warnings and Advisories

Audi has included several critical warnings within the 91VT UPDATE TSB that both technicians and owners should be aware of:

• Software Update Method: "DO NOT USE Guided Fault Finding (GFF) to perform this flash. Using GFF will cause the flash to take longer. Requests for additional time will not be considered." This emphasizes the importance of following the prescribed "Audi Flashing" method.
• Battery Voltage: "Battery voltage must remain above 12.5 volts (or higher, if directed in the work instructions) for the duration of the software update. Failure to do so may cause the update to fail, which could result in damage to the control module. Control modules damaged by insufficient voltage will not be covered."
• Tester Power: "Under no circumstances should the tester be used on battery power alone during the software update. Failure to do so may result in the tester powering off during the update, which could result in damage to the control module."
• Connectivity: "Performing a software update using a Bluetooth or Wi-Fi connection increases the risk of losing connection during the update, which could result in damage to the control module. It also greatly increases the time required to perform the update. Requests for additional time or parts will be denied if the GFF log shows the update was performed using Bluetooth or WiFi."
• Radiator Fan Safety: "Radiator Fan(s) may cycle ON high speed during the Update Process! 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 Radiator Fan(s) during Update Process!"
• Warranty Claims: "The SVM Process must be completed in its entirety so the database receives the update confirmation response. A warranty claim may not be reimbursed if there is no confirmation response to support the claim." Also, "The ELSA system is the only binding inquiry and verification system; other systems are not valid and may result in non-payment of a claim."
• Customer Presets: "As a best practice, customer presets should be documented prior to performing any update in the event these settings are lost during the update."
• Refrigerant Handling: "Danger of frostbite due to refrigerant coming out under pressure. Frostbite on the skin and other parts of the body is possible." Additionally, "If more than 10 minutes elapse after extracting or draining the refrigerant and the refrigerant circuit has not been opened, extract or drain the refrigerant again. Pressure develops in the refrigerant circuit due to evaporation."

Detailed Repair Procedure

The 91VT UPDATE involves specific steps depending on the identified criteria (K1, 01, 02, 03). All procedures require the vehicle to be within its New Vehicle Limited Warranty and for the 91VT code to be present in the ELSA Campaign/Action Information screen.

Air Conditioning Sensor Inspection and Replacement (Criteria K1)

For vehicles exhibiting air conditioning issues, the repair begins with inspecting the refrigerant pressure/temperature sensors G395, G826, and G827. Technicians are advised to access these sensors without removing them and to avoid recovering the refrigerant charge during the inspection phase. The inspection involves checking for a green dot on all three sensors. If a green dot is present on all sensors, no replacement is necessary. If a green dot is absent, the production date of the sensor must be checked. Sensors produced on or before calendar week 31 of 2021 require replacement.

If replacement is needed, safety precautions must be followed due to the risk of frostbite from refrigerant. The refrigerant system must be evacuated or drained, and the refrigerant circuit opened immediately. If more than 10 minutes pass, the refrigerant must be drained again. The affected sensor(s) are then replaced according to the ELSA repair manual, and the A/C system is recharged with the appropriate amount of R1234yf refrigerant.

Software Updates (Criteria 01, 02, 03)

Software updates are a crucial part of the 91VT UPDATE, addressing issues like the Audi RS e-tron GT gearbox error and charging problems. Before initiating any software update, several prerequisites must be met:

1. ODIS Software: Ensure the ODIS software on the VAS Diagnostic Tester (VAS6150X/VAS6160X) is completely up to date.
2. Battery Charger: Connect a VAS5908 battery charger (or equivalent with at least 90A) to the vehicle battery, ensuring voltage remains above 12.5 volts throughout the update. The charger must be switched off and on, its display off before restarting, and set to a charging voltage of 14.8 Volt (access code 6161 or DIAG+ mode). The charger's voltage must be restored to its original value after the update.
3. Tester Settings: Turn off screen saver and power saving settings on the diagnostic tester.
4. Connectivity: The VAS Diagnostics Interface MUST ONLY be connected to the tester with a USB cable; Bluetooth or Wi-Fi connections are prohibited.
5. Pre-Scan: Perform a full diagnostic scan using GFF and send the diagnostic protocol online, saving the session.
6. Bus Sleep: After the diagnostic scan, perform a bus sleep for at least five minutes with the 12V charger disconnected, diagnostic interface removed, and all doors, hood, and rear lid closed until all interior lights turn off.
7. Vehicle Preparation: Switch off all consumers (air conditioning, heater blower motor, lights, heated seats, etc.). Reconnect the battery charger, ensure the latest ODIS is downloaded, the diagnostic head is connected via USB, and the selector lever is in 'P'.
8. Update Execution: Only start the software update when the ODIS tester shows voltage above 14V. Use operating mode FLASH with communication path CAN. Select "SVM – Code Input".
   • For criteria 01 and 02 (or 02 alone), enter SVM code SWVGTA001.
   • For criteria 03, enter SVM code 91VTA396. Follow on-screen prompts. If the error message "High-voltage charging active - precondition not met" appears, deactivate the HV system, perform the update, then reactivate the HV system. If "Configuration on control unit 0046 – convenience system central module could not be performed" appears, select option #1 and "Complete/Next tab" and continue the update without creating a TAC case.
9. Post-Update: Send the diagnostic log to GFF Paperless. Check the instrument cluster for any fault messages or warning lamps. If parking brake warnings persist, perform test plan "0003 – calibrate parking brake" via guided functions for diagnostic address 0003.

Required Parts

For sensor replacement (Criteria K1), the following parts may be required:

• AC Pressure Sensor: Part Number 4M0-959-603-E (up to 3 units)
• Oil Refrigerant: Part Number G-052-535-M2 (up to 1.6 ml)
• A/C Refrigerant - R1234yf: Up to 3.46 oz (98 g) for USA, or up to 98 g for Canada. This is considered an outside material.

Audi states there will be no initial parts allocation for this campaign, and parts should be ordered as per the information in this circular. The ordering system will supersede the part if applicable.

Special Tools

Performing the 91VT UPDATE requires several specialized tools:

• Battery Tester/Charger: VAS5908 (or equivalent, >= 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

Warranty Information

This Customer Satisfaction Package (NVLW) is covered under the New Vehicle Limited Warranty. The Service Number for this action is 91VT, with a Damage Code of 0099 and Parts Vendor Code 002. Claim types are 7 10 for sold vehicles and 7 90 for unsold vehicles.

Labor operations and time units vary based on the criteria:

• For Criteria 01, 02, or 03 (Software Update Only):

  • Battery charge: Labor Op 2706 89 50 (SEE ELSA time units)
  • Software update (includes preliminary and follow-up work): Labor Op 0151 00 40 (100 time units)
  • Optional (if HV system deactivation or parking brake calibration needed): Disable HV system voltage deactivate and activate (Labor Op 9310 83 00, SEE ELSA time units) and GFF/Guided functions (Labor Op 0150 00 60, time stated on diagnostic protocol).

• For Criteria K1, 01, 02 (Sensor Check/No Replacement + Software Update):

  • Includes wheel, cowl panel, storage compartment remove/reinstall, check 3 pressure sensors, battery charge, and software update. Specific Labor Ops include 4405 19 51, 6644 19 50, 7007 19 50, 8709 01 99, 2706 89 50, 0151 00 40. Optional HV system deactivation and GFF operations as above.

• For Criteria K1, 01, 02 (Sensor Replacement + Software Update):

  • Includes all operations for sensor check/no replacement, plus refrigerant drain/fill (Labor Op 8703 17 00). Specific sensor replacement Labor Ops are provided: 8709 20 50 (all three sensors), 8709 19 50 (G395), 8709 19 51 (G826), 8709 19 52 (G827).

Dealers are instructed to mark labor as causal. If criteria K1 is not assigned, labor is causal. If K1 is assigned, labor is causal if all sensors are OK, but any specific sensor that is NOT OK should be marked as causal. Dealers are explicitly told, "Do not claim wash/loaner under this action."

Owners will not receive a separate notification for this update. It is important to contact an authorized Audi dealer to verify if your vehicle is affected and to schedule the necessary service.

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Source: NHTSA ID: 11009238