2022-2023 Audi e-tron GT / RS e-tron GT Gearbox & AC Issues

Audi has issued Technical Service Bulletin 91VT UPDATE, a Customer Satisfaction Package (NVLW), for certain 2022-2023 Audi e-tron GT and RS e-tron GT models. This proactive update aims to prevent several potential issues, ensuring optimal vehicle performance and owner satisfaction. The 91VT UPDATE covers conditions ranging from air conditioning malfunctions to critical powertrain and charging system concerns.

Symptoms

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

• Air Conditioning Malfunction (Criteria K1): The air conditioning system may not work due to failing pressure and temperature sensors. This can lead to discomfort, especially in varying climates.
• Gearbox Error Message (Criteria 01): After turning off the engine by pressing the start/stop button, the gearbox lock might not fully engage or release. This can result in a warning message on the instrument cluster stating, "gearbox error, max 120km/h, go to workshop." This condition prevents the gearbox lock from releasing, potentially impacting vehicle operation.
• High-Voltage Charging Issues (Criteria 02): The vehicle may display an "Unauthorized display of the Turtle LED for a short time when KL15 is off (HV system in the state 'not ready to drive')". Additionally, owners might experience "charging duration loop at <100% or charging abort (red LED) possible," leading to "Fast charging no longer possible."

Diagnosis and Trigger Conditions

To determine if a vehicle is affected by the 91VT UPDATE, an authorized Audi dealer will check the vehicle's eligibility using the ELSA Campaign/Action Information screen. This system is the only valid source for verification.

For the air conditioning issue (Criteria K1), technicians will inspect the G395, G826, and G827 refrigerant pressure/temperature sensors. The presence or absence of a green dot on these sensors, along with their production date, helps determine if replacement is necessary.

The gearbox error (Criteria 01) and high-voltage charging issues (Criteria 02) are addressed through software updates. These conditions are typically identified by the specific warning messages or operational failures described above.

Important Warnings and Owner Advisories

Audi has provided several critical warnings and advisories for technicians performing the 91VT UPDATE, which owners should also be aware of:

• Refrigerant Handling: During the inspection of refrigerant pressure/temperature sensors, technicians are advised, "Do not recover the refrigerant charge during the inspection section." If replacement is needed, proper safety precautions, including wearing safety gloves and protective eyewear, are mandatory due to the risk of frostbite from refrigerant exposure.
• Software Update Procedures:
  • Technicians MUST NOT USE Guided Fault Finding (GFF) to perform the software flash, as this will prolong the process and requests for additional time will not be considered.
  • The VAS Diagnostics Interface MUST ONLY be connected to the tester with a USB cable. Performing updates via Bluetooth or Wi-Fi increases the risk of connection loss and control module damage, and requests for additional time or parts will be denied if the GFF log shows wireless connection was used.
  • A battery charger (e.g., VAS5908) must be connected to the vehicle battery and remain connected throughout the software update. The battery voltage must stay above 12.5 volts. "Control modules damaged by insufficient voltage will not be covered."
  • The battery charger settings should NOT be changed in a way that could damage the charger or the vehicle. After the software update, the battery charger must be restored to its original voltage value.
  • "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!"
• Error Handling: If the software update fails for any reason, ODIS feedback must be sent prior to further diagnosis. Failure to do so may result in non-payment of consequential requests for additional time or parts.
• High-Voltage System: If a "High-voltage charging active - precondition not met" error message appears after the software update, the high-voltage system must be deactivated and then reactivated, and the software update performed again.

Repair Procedure Summary

The repair for the 91VT UPDATE involves either sensor inspection/replacement or software updates, depending on the identified criteria.

Criteria K1: Air Conditioning Sensor Inspection and Replacement

1. Sensor Access: Technicians will access the G395, G826, and G827 refrigerant pressure/temperature sensors. These sensors are typically located within the air conditioning refrigerant circuit.
2. Visual Inspection: Each sensor is inspected for a green dot. If a green dot is present on all three sensors, they do not require replacement.
3. Production Date Check: If a green dot is not present on any of the sensors, the technician checks the sensor's production date. Sensors produced on or before calendar week 31 of 2021 require replacement.
4. Sensor Replacement: If replacement is necessary, the refrigerant circuit is evacuated or drained. The affected sensor(s) are then replaced according to ELSA repair manual instructions. The part number for the AC pressure sensor is 4M0-959-603-E.
5. System Recharge: After replacement, the A/C system is recharged with the appropriate amount of R1234yf refrigerant.

Criteria 01, 02, and 03: Combined Software Update

This procedure applies to vehicles exhibiting the 2022 Audi RS e-tron GT gearbox error or high-voltage charging issues. The software update is a critical component of the 91VT UPDATE.

1. Pre-Update Preparation:
   • Ensure the ODIS software is fully updated.
   • Connect a battery charger (e.g., VAS5908) to the vehicle, ensuring battery voltage remains above 12.5 volts. The charger must be set to a charging voltage of 14.8V.
   • Disable screen saver and power saving settings on the diagnostic tester.
   • Plug the VAS Diagnostic Tester directly into the vehicle via a USB cable.
   • Switch off all vehicle consumers (AC, heater, lights, heated seats, etc.).
   • Move the selector lever to 'P'.
2. Diagnostic Scan and Bus Sleep: Perform a full diagnostic scan using GFF and send the diagnostic protocol online. After the scan, disconnect the 12V charger and diagnostic interface, close all doors/hood/rear lid, and wait for a bus sleep of at least five minutes.
3. Software Flash: Reconnect the battery charger and diagnostic head. Only start the software update when the voltage displayed in ODIS is above 14V. Use the 'FLASH' operating mode with a 'CAN' communication path. Select 'SVM – Code Input' and enter the specific SVM code: SWVGTA001 for criteria 01 and 02, or 91VTA396 for criteria 03.
4. Post-Update Checks:
   • Verify that no fault messages or warning lamps are present in the instrument cluster.
   • Perform another bus sleep for at least five minutes.
   • If parking brake warnings persist, perform a parking brake calibration using the test plan "0003 – calibrate parking brake" in diagnostic address 0003.
   • Ensure the diagnostic log is sent to GFF Paperless.
   • Restore the battery charger to its original voltage value.

Required Tools and Parts

Performing the 91VT UPDATE requires specific tools and parts to ensure the repair is completed correctly.

Parts:

• 4M0-959-603-E: AC pressure sensor (up to 3 units)
• G 0525351M: Oil Refrig (up to 1.6 ml)
• R1234yf refrigerant: (up to 98g, locally sourced)

Special Tools:

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

Owner Action

If you own a 2022-2023 Audi e-tron GT or RS e-tron GT and experience any of the described symptoms, or if you wish to confirm if your vehicle is covered by the 91VT UPDATE, you should contact an authorized Audi dealer. This Customer Satisfaction Package is typically performed under warranty. The dealer will verify your vehicle's eligibility using the ELSA system and perform the necessary inspections, sensor replacements, and software updates. It is important to address the 2022 Audi RS e-tron GT gearbox error and other issues promptly to maintain your vehicle's safety and performance.

NHTSA ID: 11009253