2020-2022 Audi e-tron A/C System Failure (Service Action 87H9)

Symptoms

Owners of affected 2020-2022 Audi e-tron vehicles may experience a complete failure of the air conditioning system. This means the A/C will no longer function, leading to a loss of cooling or heating capabilities from the system. This condition is directly linked to the malfunction of specific pressure and temperature sensors, specifically the G395 and G826 sensors.

Diagnosis and Trigger Conditions

Audi Service Action 87H9 outlines a specific diagnostic procedure for technicians to identify the root cause of the Audi e-tron A/C system failure. The primary step involves a visual inspection of the G395 and G826 pressure and temperature sensors located within the vehicle's air conditioning system.

Technicians will check for a green dot on the connector housing of both the G395 and G826 sensors. If this green dot is present on both sensors, they are considered to be functioning correctly and do not require replacement. In this scenario, the technician will proceed with reassembly.

However, if the green dot is absent from one or both sensors, further investigation is required. The technician will then check the production date of the affected sensor, which is typically found on the sensor itself in a week/year format. Sensors manufactured between calendar week 23 of 2020 and calendar week 30 of 2021 are identified as potentially faulty and will require replacement. If the production information is not easily visible, a mirror can be used to aid in the inspection. This precise date range helps to identify the specific batch of sensors prone to failure, which can lead to the Audi e-tron A/C system failure.

Repair Procedure Summary

Addressing the Audi e-tron A/C system failure under Service Action 87H9 involves a detailed inspection and, if necessary, replacement of the faulty pressure and temperature sensors. The process begins with the technician removing the front luggage compartment liner to gain access to the sensor locations in the under-hood compartment.

Due to the nature of the air conditioning system, which involves high-voltage components and refrigerants, strict safety precautions must be observed. Technicians are required to wear safety gloves and protective eyewear to prevent frostbite from refrigerant exposure and to avoid hazards associated with the high-voltage system. Before any components are removed, the A/C system's refrigerant must be evacuated or drained. The power-activated valves within the refrigerant circuit must also be opened through the ODIS diagnostic system prior to refrigerant recovery to ensure safe handling.

Once these preparatory steps are complete, the affected pressure and temperature sensors (G395 and/or G826) are replaced. The connectors for these sensors can be swapped, so technicians must ensure they are reinstalled in their correct locations if removed. The replacement procedure follows specific, detailed instructions provided in the ELSA repair manual. For the G395 sensor, the path is Repair manual > Heating, Ventilation & Air Conditioning > Heating Ventilation and Air conditioning > 87 Air Conditioning > Refrigerant Circuit > A/C Pressure/Temperature Sensor G395, Removing and Installing. For the G826 sensor, the path is Repair manual > Heating, Ventilation & Air Conditioning > Heating Ventilation and Air conditioning > 87 Air Conditioning > Refrigerant Circuit > A/C Pressure/Temperature Sensor 2 G826, Removing and Installing. After the new sensors are installed, any additional basic settings recommended by the diagnostic test plan are performed to integrate the new components correctly.

Finally, the A/C system is recharged with the precise amount of R1234yf refrigerant that was recovered. The vehicle is then reassembled, which includes reinstalling the front luggage compartment liner and replacing the foam insert for tool storage, ensuring all components are properly secured.

Required Tools and Parts

To perform Service Action 87H9 and rectify the Audi e-tron A/C system failure, specific parts and specialized tools are necessary:

Required Parts:

• SENSOR (Part Number: 4M0-959-603-E): Up to two units may be needed for sensor replacement.
• BIN (Part Number: 4KE-012-113-A): One unit, specifically a tool storage insert, to be replaced after removal.
• BIN (Part Number: 4KE-863-362-B): One unit, specifically a storage bin, to be replaced after removal.
• OIL REFRIG (Part Number: G-052-535-1M-DSP): Up to 1.2 ml of refrigerant oil.
• R1234yf refrigerant: Up to 74g, to be sourced locally.
• RIVET (Part Number: N 90558401): Up to four units, used during reassembly.

Special Tools and Equipment:

• R1234yf Air Conditioning Service Unit: Model ROB1234YFX- or VAS581005-. Essential for safely evacuating and recharging the A/C system.
• Engine Bung Set: Model VAS6122-. Used to seal openings during the repair process.
• Socket - 24mm: Model T40284-. A specialized socket for sensor removal or installation.
• Diagnostic Tester: Model VAS6150X/6160X-. Required for system diagnostics, opening A/C valves via ODIS, and performing basic settings.
• Battery Tester/Charger: Must be capable of providing a minimum of 90 Amp continuous supply to maintain stable vehicle power during the procedure.
• Safety Gloves and Safety Goggles: Crucial personal protective equipment for technicians when handling refrigerants and working near high-voltage systems.

Warranty Information

For Service Action 87H9, Audi provides specific claim entry instructions for dealerships. The Service Number is 87H9, the Damage Code is 0099, and the Parts Vendor Code is 002. For sold vehicles, the Claim Type is 7 10, and for unsold vehicles, it is 7 90. The Causal Indicator should be marked as causal if the SENSOR is OK, or SENSOR* if a sensor(s) is NOT OK. The Criteria I.D. for this action is GE, indicating a pressure/temperature sensor inspection.

Labor Operations and Time Units:

• Inspection (Check sensor production dates): Labor Op 8711 01 99, 10 Time Units.
• Inspection (Storage compartment remove+reinstall): Labor Op 7007 19 00, Time Units as per ELSA.
• Replacement (2 Pressure switch remove+reinstall, if both sensors replaced): Labor Op 8709 20 51, Time Units as per ELSA.
• Replacement (High pressure switch remove+reinstall, only if G395 sensor replaced): Labor Op 8757 19 50, Time Units as per ELSA.
• Replacement (Low pressure switch remove+reinstall, only if G826 sensor replaced): Labor Op 8764 19 50, Time Units as per ELSA.
• Refrigerant drain+fill: Labor Op 8703 17 00, Time Units as per ELSA.
• Connect battery charge: Labor Op 2706 89 50, Time Units as per ELSA.
• GFF/Guided functions: Labor Op 0150 00 00, Time Units as stated on diagnostic protocol.

Important Warnings for Owners

Audi has provided specific instructions and warnings regarding Service Action 87H9 that owners should be aware of. Notably, Audi states, "Dealers must ensure that every affected inventory vehicle has this campaign completed before delivery to consumers." This means that if you are purchasing a 2020-2022 Audi e-tron, whether new or used, that falls within the affected range, the dealership is obligated to perform this service action before you take delivery of the vehicle.

Furthermore, this service action will be performed free of charge for owners. However, this complimentary service has an expiration date: "This service action will be available for you free of charge only until September 01, 2028." If you choose to have the work performed after this date, you will be responsible for the normal dealership costs associated with the repair. Owners should also note that Audi explicitly states, "Do not claim wash/loaner under this action," meaning these services are not covered as part of this campaign.

Owner Action

If you own a 2020-2022 Audi e-tron and are experiencing an Audi e-tron A/C system failure, or if you wish to ensure that your vehicle's pressure and temperature sensors are functioning correctly, it is recommended to take action. Contact an authorized Audi dealer as soon as possible to schedule an appointment for Service Action 87H9.

The inspection and any necessary repairs will be performed free of charge by the dealership. The estimated time for this work is approximately four hours, though your dealer may require additional time for preparation and to accommodate their workshop schedule. To verify if your specific vehicle is covered by this or any other recall or service campaign, you can use the Recall/Service Campaign Lookup tool available on www.audiusa.com by entering your Vehicle Identification Number (VIN).

Source: NHTSA Manufacturer Communication 10250344.