2022-2023 Audi e-tron GT Software Update & Sensor Fix

Audi has issued Technical Service Bulletin (TSB) 91VT UPDATE, a Customer Satisfaction Package (NVLW), to proactively address several potential issues in certain 2022-2023 Audi e-tron GT and RS e-tron GT vehicles. This update involves both hardware inspection and replacement for air conditioning sensors, as well as critical software updates for vehicle control modules. The primary goal is to prevent conditions that could lead to air conditioning malfunctions, gearbox warnings, and high-voltage charging difficulties. Owners experiencing these symptoms should contact an authorized Audi dealer to determine if their vehicle is covered by this important Audi e-tron GT software update.

Symptoms and Technical Background

This 91VT UPDATE addresses several distinct conditions that owners might encounter:

• Air Conditioning Malfunction (Criteria K1): Air conditioning pressure and temperature sensors may fail, leading to a non-functional air conditioning system.
• Gearbox Lock Warning (Criteria 01): After turning off the engine, 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."
• Charging System Issues (Criteria 02): Vehicles may display an unauthorized "Turtle LED" for a short period when the ignition is off, indicating the high-voltage (HV) system is "not ready to drive." Owners might also experience charging duration loops at less than 100%, charging aborts with a red LED, and an inability to perform fast charging.
• Combined Issues (Criteria 03): This refers to vehicles exhibiting both the gearbox lock warning (Criteria 01) and the charging system issues (Criteria 02).

Owner-Facing Messages

Owners may see the following specific messages or indicators related to these issues:

• "gearbox error, max 120km/h, go to workshop"
• HV system in the state "not ready to drive"
• Red LED indicating a charging abort
• "High-voltage charging active - precondition not met" (during software updates)
• "Configuration on control unit 0046 – convenience system central module could not be performed" (during software updates)

Important Warnings for Owners

Audi has provided several critical warnings and advisories related to this 91VT UPDATE:

• Software Update Precautions: Technicians are explicitly instructed NOT to use Guided Fault Finding (GFF) for the software flash, as it can prolong the process and may lead to denied warranty claims for additional time. Updates should only be performed via a direct USB connection, as Bluetooth or Wi-Fi connections increase the risk of data loss and control module damage.
• Battery Charger Settings: It is crucial that the battery charger's settings are not altered in a way that could damage the charger or the vehicle. Insufficient charging voltage during a software update can damage control units.
• Radiator Fan Safety: During the update process, radiator fan(s) may cycle on at high speed. There is a serious risk of personal injury from spinning fan blades, so hands and all objects must be kept clear.
• Warranty Claims: The Software Version Management (SVM) process must be completed entirely to ensure the database receives confirmation. Warranty claims may be denied if there is no confirmation response.
• Software Update Failure: If the software update fails, ODIS feedback must be sent prior to further diagnosis to ensure proper reporting and prevent non-payment for subsequent requests.
• Customer Notification: Audi requires dealers to inform customers in writing about all work performed, including any updates completed under this action.
• No TAC Case Required: Dealers are advised NOT to create a Technical Assistance Center (TAC) case if a specific error message regarding the convenience system central module configuration appears during flashing.
• No Wash/Loaner Claim: Dealers are instructed not to claim vehicle wash or loaner services under this action.

Repair Procedure Summary

The 91VT UPDATE involves specific repair procedures depending on the identified criteria:

For Air Conditioning Sensor Issues (Criteria K1)

Technicians will first inspect the G395, G826, and G827 refrigerant pressure/temperature sensors. This inspection does not require removing the sensors or recovering the refrigerant charge. The technician checks for a green dot on all three sensors. If a green dot is present on all sensors, no replacement is needed. If any sensor lacks a green dot or was produced on or before calendar week 31 of 2021, it requires replacement. Replacement involves evacuating the refrigerant, replacing the affected sensor(s) (part number 4M0-959-603-E), and then recharging the A/C system with R1234yf refrigerant.

For Gearbox Lock and Charging Issues (Criteria 01, 02, 03)

These issues are resolved through an Audi e-tron GT software update. The process requires several preconditions to be met before launching the VAS Diagnostic Tester:

1. ODIS Software: Ensure the ODIS software is completely up to date.
2. Battery Management: A battery charger (such as VAS5908) must be connected to the vehicle battery and remain connected throughout the update. Battery voltage must stay above 12.5 volts (or 14.8V as shown in ODIS during the flash). The charger must be restored to its original voltage value after the update.
3. Tester Configuration: Screen saver and power-saving settings on the diagnostic tester must be off. The VAS Diagnostic Tester (VAS6150X/VAS6160X) must be plugged in via its power adapter and connected to the vehicle using a USB cable.
4. Pre-Update Steps: Perform a full diagnostic scan using GFF and send the protocol online. Then, disconnect the 12V charger and diagnostic interface, close all doors/hood/rear lid, and wait for a five-minute bus sleep. Reconnect the charger, switch off all vehicle consumers (AC, lights, heated seats), and ensure the selector lever is in 'P'.
5. Software Flash: The update is performed using the 'FLASH' operating mode with a CAN communication path. Technicians enter specific SVM codes, such as SWVGTA001 or 91VTA396, and follow on-screen prompts.
6. Post-Update Checks: After the Audi e-tron GT software update, a five-minute bus sleep is performed. The instrument cluster is checked for fault messages. If parking brake warnings persist, the "0003 – calibrate parking brake" test plan is executed to ensure proper function.

Service Action 93P9 must be performed before completing this software update.

Required Parts

For sensor replacement, the following parts may be needed:

• 4M0-959-603-E: AC pressure sensor (up to 3 units)
• G-052-535-M2: OIL REFRIG (up to 1.6 ml)
• R1234yf refrigerant: (up to 98g, locally sourced)

Special Tools

Authorized Audi service facilities will utilize specialized tools for these procedures:

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

Warranty Information

This 91VT UPDATE is covered under the New Vehicle Limited Warranty. Dealers are instructed to enter claims as soon as possible after completing the campaign work. Specific labor operations are provided for various aspects of the repair, including battery charging (2706 89 50), software updates (0151 00 40), HV system deactivation (9310 83 00), GFF operations (0150 00 60), and sensor removal/replacement (e.g., 8709 20 50, 8709 19 50, 8709 19 51, 8709 19 52, 4405 19 51, 6644 19 50, 7007 19 50, 8709 01 99, 8703 17 00).

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NHTSA ID: 11009223