2021 Audi Q5 e / A7 e Electrical System Malfunction TSB

Owners of certain 2021 Audi Q5 e and A7 e vehicles may encounter an Audi Q5 e electrical system malfunction indicated by a specific warning message and diagnostic trouble code. This Technical Service Bulletin (TSB) 93 24 91 2059309/7, which supersedes TSB 24-56 dated May 16, 2024, provides a software-based solution for this condition.

Symptoms

Drivers may notice several symptoms related to an Audi Q5 e electrical system malfunction:

• When the "ignition" is switched on, a red warning light appears, and the vehicle cannot be moved.
• The vehicle does not start.
• In the instrument cluster, a red battery symbol (as depicted in Figure 1 of the TSB) is displayed with the text "Electrical system: Malfunction! Safely turn off vehicle".
• After turning the car off and then on again, the warning light typically disappears, and the vehicle functions normally.

Fault Codes / DTCs

When diagnosing this issue, technicians will find the following Diagnostic Trouble Code (DTC) stored in the hybrid battery management module, J840 (address word 008C):

• P0AC000: Hybrid/EV Battery Pack Current Sensor "A" Circuit Range/Performance.

Other event memory entries may also be logged in address 008C in combination with P0AC000, including:

• P33F000
• U059B00

Technical Background

The root cause of this Audi Q5 e electrical system malfunction is an internal communication issue. Specifically, the communication between the Battery Junction Box (BJB – SX6) electronics and the current/voltage sensor can become inaccurate under unusual conditions. This leads to the system registering a fault and triggering the warning message.

Important Warnings

Audi has issued critical advisories for technicians performing this software update:

• To prevent damage to high-voltage components, the high-voltage charging cable on vehicles must be unplugged BEFORE the SVM code is entered during the software update. Charging the high-voltage battery during this process can cause damage.
• Ensure the diagnostic scan tool is updated to its latest level to prevent the flashing procedure from failing.
• The SVM update requires a specific sequence: "SVM code 1 before SVM code 2". If this order is not followed precisely or if the procedure is not completed, it may render the vehicle inoperable.

Repair Procedure Summary

The repair involves updating the software for the Hybrid Battery Management module (J840) and/or the Battery Junction Box (SX6) using the Software Version Management (SVM) system. This process requires adherence to TSB 2011732, "00 Software Version Management (SVM), operating instructions."

1. Identify Control Modules: Technicians use a diagnostic scan tool to access the hybrid battery management module, J840 (address word 008C), and select "Guided Functions" (as shown in Figure 2 of the TSB). They then identify the software and hardware versions of the J840 and its slave module, the Battery Junction Box (SX6), which is typically the first slave module displayed (Figure 5).
2. Compare Software Versions: The identified software and hardware versions are compared against a table of affected and improved software versions provided in the TSB. If the vehicle has affected software in either the J840 or SX6, an update is required.
3. Perform SVM Update: Two specific SVM action codes must be performed in the correct order. The first SVM code, 8CA006, updates the software for the J840 and SX6 modules. The second SVM code, 8CA006KONF, is also applied to the J840 module. After both SVM updates are completed, the installed software versions should match the target software levels specified in the TSB.

Affected Software and Hardware Versions

The TSB details specific software and hardware part numbers that are affected and their corresponding improved versions. For the J840 control module, affected software part numbers like 4K0915233 (version 0275) and 4M0915233R (version 0274) are updated to improved versions such as 4K0915233A (version 0278) and 4M0915233AE (version 0278). Similarly, for the SX6 control module, affected software part numbers like 4K0915254C (version 0205) and 80A915253C (version 0103 or 0105) are updated to improved versions like 4K0915254D (version 0206) and 80A915253E (version 0106).

Warranty Information

This repair is covered under warranty with the following details:

• Claim Type: 9327
• Damage Code: 0040
• Labor Operations: Software Updates (0151 0000) and Charge Battery (2706 8950).
• Diagnostic Time: No allowance for Guided Fault Finding (GFF) or checking/clearing fault codes, as these are included in existing labor operations.
• Claim Comment: As per TSB 2059309/7.

All warranty claims must comply with the Audi Warranty Policies and Procedures Manual.

Owner Action

If you own a 2021 Audi Q5 e or A7 e and experience an Audi Q5 e electrical system malfunction with the