2022-2024 Audi A3 S3 RS 3 Airbag Warning Light TSB 2072076/1

Symptoms of Incorrect Airbag Harness Routing

Owners of 2022-2024 Audi A3, S3, and RS 3 vehicles may notice two primary issues related to this problem. The most immediate concern is when the "airbag warning light is on" in the instrument cluster. This light signals a potential malfunction within the vehicle's Supplemental Restraint System (SRS), which includes airbags.

Another symptom reported by customers is that it is "difficult to activate the horn at the six o'clock position". This suggests an issue with the electrical connection or physical movement of the horn mechanism, which shares components or wiring with the airbag system in the steering wheel.

Diagnostic Trouble Codes (DTCs)

When these symptoms occur, a workshop diagnosis using a specialized scan tool will likely reveal specific Diagnostic Trouble Codes (DTCs) stored in the airbag control module, identified as -J234- (address word 0015). The relevant DTCs are:

• DTC B120E11: driver airbag release valve igniter Short circuit to Ground (GND)
• DTC B100011: driver airbag igniter Short circuit to Ground (GND)

These codes specifically point to electrical issues within the driver's airbag igniter circuit, indicating a short circuit to ground. This condition directly contributes to the illumination of the "Audi S3 airbag warning light" and can affect related components like the horn.

Technical Background

Audi Technical Service Bulletin 2072076/1 identifies the root cause of these issues as incorrect routing of the driver airbag wire harness. During vehicle assembly, the wire harness may not have been routed optimally, leading to potential chafing, pinching, or stress on the wiring. Over time, this can cause a short circuit, triggering the airbag warning light and affecting horn operation.

Audi has implemented an improved routing of the airbag wire harness in production to prevent this issue in newer vehicles.

Repair Procedure Summary

Addressing the incorrect wire harness routing involves a multi-step process for technicians. The procedure outlined in TSB 2072076/1 ensures proper diagnosis and repair:

1. Driver Airbag Removal: The first step requires carefully removing the driver airbag unit. This process follows specific guidelines detailed in the Elsa repair manual under "Body >> Body Interior >> 69 Passenger Protection, Airbags, Seat belts >> Driver Side Airbag >> Airbag Unit with igniter, Removing and Installing."
2. Wire Harness Inspection: Once the airbag is removed, technicians must thoroughly inspect the routing of the driver airbag wire harness. Special attention is given to two key areas: the round airbag and the square airbag. Figures 1-5 in the TSB document provide visual guidance for identifying correctly and incorrectly routed or damaged wiring. Figure 1 illustrates areas to inspect for damage and routing, while Figure 2 shows an example of a damaged wire harness. Figures 3 and 4 offer additional views of potential damage and routing issues, and Figure 5 provides a final check for proper routing.
3. Harness Replacement: If the inspection reveals damage or improper routing, the driver airbag wire harness must be replaced. During reinstallation of the new harness and the driver airbag, technicians must meticulously observe the correct cable routing to prevent recurrence of the issue.
4. Clear Fault Codes: After the repair is complete and the driver airbag is reinstalled, all stored fault codes in the airbag control module must be cleared using a diagnostic tool.

Required Parts and Tools

To perform this repair, specific parts and diagnostic tools are necessary:

Required Parts

• Airbag harness: Part numbers 8Y0971589 or 83971589B. Technicians should verify the correct part number with their Parts Department and/or ETKA.
• Fasteners, Bolts, Nuts, and Screws: As needed per the repair manual, available via ETKA/ELSA.

Required Tools

• VAS 6160/VAS 6150: A VAS tester with the current version of ODIS (Windows 10) is required for diagnostic procedures and clearing fault codes.

Important Warranty Information

Audi provides specific warranty coverage details for this Technical Service Bulletin 2072076/1:

• Claim Type 110: This repair is covered for vehicles up to 48 months or 50,000 miles, whichever comes first.
• Claim Type G10: Certified Pre-Owned (CPO) vehicles are also covered; however, ownership must be verified.
• Out-of-Warranty Vehicles: If your vehicle falls outside of these warranty parameters, this Technical Service Bulletin is for informational purposes only. This means that the repair cost may not be covered by Audi warranty.

Warranty claims must be submitted in accordance with the Audi Warranty Policies and Procedures Manual and are subject to review or audit by Audi Warranty.

Labor Operations and Diagnostic Time

• Service Number: 9766
• Damage Code: 0024
• Labor Operations:
  • Driver airbag unit remove+reinstall: 6958 1900
  • Driver airbag harness replace: 9766 5599 (10 TU)
• Diagnostic Time (GFF): 0150 0060 (Maximum 30 TU)
• Road Test: No allowance (0 TU) is provided for road tests both prior to and after the service procedure.

What Owners Should Know

If you own a 2022-2024 Audi A3, S3, or RS 3 and are experiencing an "Audi S3 airbag warning light" or difficulty activating your horn, it is recommended to contact your authorized Audi dealership. Reference TSB 2072076/1 when discussing these symptoms. The dealership will be able to diagnose the issue, confirm the presence of DTCs B120E11 or B100011, and perform the necessary inspection and repair of the driver airbag wire harness.

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Source: NHTSA ID: 10245682