2022-2023 Audi e-tron GT AC, Charging, & Gearbox Issues TSB 91VT

Audi has released Technical Service Bulletin (TSB) 91VT, also known as the Customer Satisfaction Package – (NVLW), to address various potential issues affecting 2022-2023 Audi e-tron GT and RS e-tron GT vehicles. This proactive update aims to prevent problems related to the air conditioning system, gearbox operation, and high-voltage charging capabilities. Owners experiencing any of the described symptoms should contact an authorized Audi dealer to have the 91VT UPDATE performed.

This TSB covers specific conditions that could lead to malfunctions in several critical vehicle systems. The remedies involve either inspecting and potentially replacing air conditioning sensors or performing software updates to the convenience system and high-voltage battery control modules. Addressing these Audi e-tron GT AC charging gearbox issues ensures optimal vehicle performance and prevents future complications.

Symptoms and Technical Background

Owners of affected 2022-2023 Audi e-tron GT and RS e-tron GT vehicles may encounter one or more of the following symptoms, categorized by specific criteria outlined in TSB 91VT:

• Criteria K1: Air Conditioning Malfunction. On Audi vehicles from a certain production period, the air conditioning pressure temperature sensors (G395, G826, G827) may fail. This can result in the air conditioning system not working properly.
• Criteria 01: Gearbox Lock Issue. After turning off the engine by pushing 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".
• Criteria 02: Charging and High-Voltage System Anomalies. This condition involves the unauthorized display of the Turtle LED for a short period when the ignition (KL15) is off, indicating the high-voltage (HV) system is in the state "not ready to drive". Owners might also experience charging duration loops at less than 100% or charging aborts (indicated by a red LED), making fast charging no longer possible.
• Criteria 03: Combined Issues. This refers to vehicles exhibiting both the gearbox lock issue (Criteria 01) and the charging/HV system anomalies (Criteria 02).

Important Warnings and Owner Advisories

Audi has provided several critical warnings within TSB 91VT to ensure safety and proper repair procedures:

• 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!"
• Diagnostic Software Use: "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." The flash process should be done through "Audi Flashing."
• Diagnostic Interface Connection: "The VAS Diagnostics Interface MUST ONLY be connected to the tester with a USB cable." Performing a software update using a Bluetooth or Wi-Fi connection increases the risk of losing connection and potential control module damage.
• Battery Charger Settings: "DO NOT change any settings that will damage the charger or the vehicle." The battery charger must be set to a charging voltage of 14.8 Volt during software updates.
• Insufficient Charging Voltage: "If the software update is performed with an insufficient charging voltage, damage to one or more control units may occur." Control modules damaged by insufficient voltage will not be covered under warranty.
• Post-Update Charger Reset: "After the software update has been performed, the battery charger must be restored to the original voltage value."
• 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."
• TAC Case Creation: If an error message "Configuration on control unit 0046 – convenience system central module could not be performed" is displayed during flashing, technicians are instructed to "DO NOT create a TAC case as this is not required."

Repair Procedure Summary

The repair process outlined in TSB 91VT varies depending on the specific criteria affecting the vehicle. Audi dealers will perform these repairs under the customer satisfaction package.

For Criteria K1 (AC Sensor Issues)

1. Sensor Inspection (Section B): Technicians will access the G395, G826, and G827 refrigerant pressure/temperature sensors without removing them or recovering refrigerant. They will check for a green dot on each sensor. If a green dot is present on all three sensors, no replacement is needed. If any sensor lacks a green dot, its production date will be checked. Sensors produced on or before calendar week 31 of 2021 require replacement. The refrigerant charge should not be recovered during this inspection section.
2. Sensor Replacement (Section C, if necessary): If one or more sensors need replacement, the refrigerant will be evacuated or drained from the system. Technicians must wear safety gloves and protective eyewear due to the danger of frostbite from refrigerant. The affected sensor(s) (Part Number 4M0-959-603-E) will then be replaced according to ELSA repair manual procedures. If more than 10 minutes elapse after draining refrigerant and the circuit has not been opened, the refrigerant must be drained again. The A/C system will then be recharged with R1234yf refrigerant.

For Criteria 01, 02, or 03 (Software Updates)

Software updates are performed for Audi e-tron GT AC charging gearbox issues related to the convenience system control module (Criteria 01), high-voltage battery control module (Criteria 02), or both (Criteria 03). The process requires strict adherence to specific conditions:

1. Pre-Update Preparations:

   • Ensure the ODIS software is completely up to date, referring to the "Current ODIS Service Version" circular in Elsa2Go Service References.
   • Connect a battery charger (VAS5908 or equivalent, rated at least 90A) to the vehicle battery and ensure voltage remains above 12.5 volts for the duration of the software update. Failure to do so may cause the update to fail and damage control modules.
   • Disable screen saver and power-saving settings on the diagnostic tester to prevent it from entering power save mode during the update.
   • Plug the VAS Diagnostic Tester (VAS6150X/VAS6160X) into a supplied power adapter. Under no circumstances should the tester be used on battery power alone.
   • The VAS Diagnostics Interface MUST ONLY be connected to the tester with a USB cable to avoid connection loss and damage to control modules.
   • Perform a full diagnostic scan using GFF and send the diagnostic protocol online. The diagnostic session should be saved for later use.
   • Perform a bus sleep for at least five minutes with the 12V charger disconnected and diagnostic interface removed. This involves closing all doors, hood, and rear lid, locking the vehicle, and waiting for all interior lighting to go off.
   • Switch off all consumers, including air conditioning, heater blower motor, lights, and heated seats.
   • Reconnect the battery charger.
   • Ensure the latest version of ODIS is downloaded.
   • Ensure the diagnostic head is connected to the ODIS tester via USB cable.
   • Move the selector lever to Park (P).
   • Service Action 93P9 must be performed before completing this software update.
   • Ensure the charger is set to a charging voltage of 14.8V; the voltage shown in ODIS must be over 14V.

2. Software Flashing (Section D/E):

   • Only start the software update when the voltage is above 14V according to the ODIS tester.
   • Use the operating mode "FLASH" with the communication path set to CAN.
   • Select "SVM – Code Input."
   • For vehicles with criteria 01 and 02, enter SVM code SWVGTA001. For vehicles with criteria 03, enter SVM code 91VTA396.
   • Follow 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, and then reactivated.

3. Post-Update Checks:

   • Check the displays in the instrument cluster; there must not be any fault messages or warning lamps.
   • Perform another bus sleep for at least five minutes with the 12V charger disconnected.
   • If warnings/messages related to the parking brake position persist, a parking brake calibration must be performed using guided functions (diagnostic address 0003, test plan "0003 – calibrate parking brake").
   • Ensure the diagnostic log is sent to GFF Paperless after completion.
   • Restore the battery charger to its original voltage value.

Required Tools and Parts

Performing the repairs for these Audi e-tron GT AC charging gearbox issues requires specific 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

Parts

• AC Pressure Sensor: Part Number 4M0-959-603-E (up to 3 required, described as "SENSOR*")
• Oil Refrigerant: Part Number G 0525351M (up to 1.6 ml, described as "OIL REFRIG")
• R1234yf Refrigerant: Locally sourced (up to 98g)

Warranty Information

This 91VT UPDATE is covered under Audi's New Vehicle Limited Warranty as a customer satisfaction package. The following details apply to warranty claims:

• Service Number: 91VT
• Damage Code: 0099
• Parts Vendor Code: 002
• Claim Type: Sold vehicle: 7 10; Unsold vehicle: 7 90
• Causal Indicator: 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.
• Vehicle Wash/Loaner: Do not claim wash/loaner under this action.

Labor Operations and Time Units:

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

Owner Action

If you own a 2022-2023 Audi e-tron GT or RS e-tron GT and experience any of the symptoms described, such as air conditioning failure, a "gearbox error, max 120km/h, go to workshop" message, or charging issues, you should contact an authorized Audi dealer. This TSB is a customer satisfaction package, meaning the repairs will be performed free of charge under the New Vehicle Limited Warranty. The dealer will verify your vehicle's eligibility using the ELSA Campaign/Action Information screen. It is important to have these Audi e-tron GT AC charging gearbox issues addressed promptly to maintain your vehicle's performance and safety.

NHTSA ID: 11009298