A871569 2020124-

Technical Service Bulletin
87 Air conditioning inoperative
87 15 69 2020124/13 August 24, 2015. Supersedes Technical Service Bulletin Group 87 number 14-49 dated April
25, 2014 for reasons listed below.
Model(s)
Year
VIN Range
Vehicle-Specific Equipment
A4
2009-2012
000001 - 999999
Not Applicable
2013
N000001 - N045670
Not Applicable
A4
A5
2008-2012
000001 - 999999
Not Applicable
A5
2013
000001 - 071355
Not Applicable
S5 / RS 5
2013
900000 - 902787
Not Applicable
A5 Cabriolet
2010-2012
000001 - 999999
Not Applicable
A5 Cabriolet
2013
000001 - 015616
Not Applicable
S5 Cabriolet /
RS5 Cabriolet
2013
900000 - 900501
A6
2005-2012
000001 - 999999
Not Applicable
A6
2013
000001 - 134357
Not Applicable
A7
2012
000001 - 999999
Not Applicable
A7
2013
000001 - 134357
Not Applicable
A8
2004-2012
000001 - 999999
Not Applicable
A8
2013
000001 - 029602
Not Applicable
Q5
2009 - 2012
000001 - 999999
Not Applicable
Q5
2013
000001 - 083307
Not Applicable
© 2015 Audi of America, Inc.
A000001 – A231729
Not Applicable
Page 1 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Condition
REVISION HISTORY
Revision
Date
Purpose
13
-
Revised Required Parts and Tools (Added sensor seal)
12
4/25/2014
Revised Warranty (Changed damage code; corrected labor operations)
11
8/26/2013
Revised header data (Added models, model years, and DTCs)
• Air conditioning is inoperative.
• The HVAC blower functions normally.
• Battery discharged; however, when charged, there is no bus silence when vehicle ignition is off.
Technical Background
• The A/C pressure/temperature sensor, G395, leaks refrigerant. This causes sensor G395 to show an incorrect
or implausible value when reading MVBs. An incorrect signal or a low refrigerant level in the system can cause
the air conditioning compressor to deactivate.
• The LIN cable connecting the vehicle electrical system control module, J519, to sensor G395 is pinched or cut.
This affects the A4/S4, A5/S5 Coupe and Cabriolet, and Q5 vehicles. The A6 and A8 are not affected by this
type of failure.
• The pressure sensor G395/G65 sends an incorrect signal that prevents bus silence and the battery is
discharged.
Tip: Sensor G395 is a LIN slave of the vehicle electrical system control module. The vehicle electrical
system control module transfers the information provided by the sensor via the comfort data bus to the climate
control module, J255.
Production Solution
An improved sensor G395 was introduced into series production and the wiring manufacturer’s processes were
optimized.
© 2015 Audi of America, Inc.
Page 2 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Service
For A4/S4 (8K), A5/S5 Coupe/Cabriolet (8T/8F), Q5, A6, A7, A8, R8:
If DTCs for sensor G395 are stored in the climate control module, J255, then check the system pressures and
refrigerant volume.
• If system pressures and refrigerant volume are low, check for refrigerant leaks at sensor G395. If a leak is
found, then replace sensor G395.
• If the system pressure and refrigerant volume are correct, perform guided fault finding (GFF). If an implausible
pressure value is found in MVB 1, field 4, then replace sensor G395.
Tip: Install only the improved G395. See part numbers in Required Parts and Tools.
Only for A4/S4 (8K), A5/S5 Coupe/Cabriolet (8T/8F), Q5:
1. Check the diagnostic fault memory for two possible DTC scenarios:
DTC Scenario 1
08 - Climate Control Module - J255:
DTC 00457 - Vehicle Electrical System Control Module – J519- Please check DTC memory
DTC 00256 - A/C Pressure/temperature Sensor –G395- Incorrect Signal
-AND09 - Vehicle Electrical System Control Module – J519:
DTC 00256 - A/C Pressure/temperature Sensor –G395- No signal/communication
DTC Scenario 2
08 - Climate Control Module - J255:
DTC 00457 - Vehicle Electrical System Control Module – J519- Please check DTC memory
DTC 00256 - A/C Pressure/temperature Sensor –G395- Incorrect Signal
-AND09 - Vehicle Electrical System Control Module – J519:
DTC 01592 - Air Quality Sensor –G238- No signal/communication
DTC 00256 - A/C Pressure/temperature Sensor –G395- No signal/communication
© 2015 Audi of America, Inc.
Page 3 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
If scenario 1 is the case, perform step 7.
If scenario 2 is the case, perform steps 2–6.
Tip: The existing LIN cable connecting the vehicle electrical system control module to sensor G395 could
be pinched or cut if scenario 2 is the case.
2. Check the LIN cable connecting the vehicle electrical system control module to sensor G395 according to
GFF.
3. Check the wire terminals in the connector at sensor G395 for proper attachment, possible corrosion, and for
any pins that may be pushed back or widened.
4. Check to make sure there is proper voltage going to the sensor and verify the ground is not intermittently open
(wiggle test).
5. Check the integrity of the wire harness.
There are two known sections in the wiring
harness that can be affected, but the
potentially affected areas are not limited to
these two known sections. One of the known
sections is in the driver’s footwell area where
the wire harness enters the interior of the car
from the engine bay (Figure 1).
Figure 1. Wire harness in driver footwell area.
© 2015 Audi of America, Inc.
Page 4 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
The second known section is in the wire
harness located under the driver’s side
headlight (Figure 2).
Figure 2. Wire harness under driver’s side headlight.
6. If a cut wire is found, install an overlay wire for the LIN bus signal. Do not attempt to repair the existing wire
harness.
a. Route the new LIN bus wire from the
vehicle electrical system control module,
J519, to the sender for sensor G395 so
that it enters the interior of the vehicle
through the driver’s side fender/lower Apillar area through the grommet indicated
in the images at right (Figures 3 and 4).
Tip: Do not route the wire through
the same opening used by the existing
wire harness.
Figure 3. Grommet in driver’s side fender/lower A-pillar area
used for pass-through for new overlay wire.
© 2015 Audi of America, Inc.
Page 5 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Figure 4. Access hole in grommet.
Tip: The LIN bus between the vehicle electrical system control module and sensor G395 may
contain a junction point shared with other modules depending on the vehicle. Ensure that the junction
points are maintained when routing the overlay.
© 2015 Audi of America, Inc.
Page 6 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
On vehicles with a charisma
switch (ride selection switch
located on the instrument
panel) route the new cable of
the sender for sensor G395 to
junction B549 (Figure 5, red
arrow).
Figure 5. Cable routing with charisma switch option.
© 2015 Audi of America, Inc.
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
b. Seal off the opening around
the wire with Butyl sealant to
prevent water intrusion (Figure
6).
Figure 6. Access hole in grommet to be sealed with Butyl sealant.
7. Replace the sender for sensor G395 and the o-ring.
© 2015 Audi of America, Inc.
Page 8 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Warranty
Claim Type:
Use applicable claim type. If vehicle is outside any warranty, this Technical Service Bulletin
is informational only.
Service Number:
8757
Damage Code:
0050
Labor Operations:
Repair front left wiring loom
9715 9999
165 TU
Drain and refill refrigerant (if necessary)
8703 1700
50 TU
Check front left wiring loom
9715 9999
175 TU
For MY 2003-2010 A8 and MY 2005-2011 A6 only:
Replace A/C pressure/temperature sensor (G395) 8709 1999
MAX 50 TU
For all other vehicles:
Replace A/C pressure/temperature sensor (G395) 8709 XXXX
Diagnostic Time:
Claim Comment:
XX TU
(See Elsa)
(See Elsa)
GFF
0150 0000
Time stated on
diagnostic
protocol
(MAX 50 TU)
Road test prior to service procedure
No allowance
0 TU
Road test after service procedure
No allowance
0 TU
As per TSB #2020124/13
All warranty claims submitted for payment must be in accordance with the Audi Warranty Policies and Procedures
Manual. Claims are subject to review or audit by Audi Warranty.
Required Parts and Tools
Part Number
Part Description
Quantity
4H0959126A
Pressure sensor
1
7H0820896
O-ring
1
© 2015 Audi of America, Inc.
Page 9 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.
Technical Service Bulletin
Additional Information
All parts and service references provided in this TSB (2020124) are subject to change and/or removal. Always
check with your Parts Department and service manuals for the latest information.
© 2015 Audi of America, Inc.
Page 10 of 10
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior
expressed written permission of the publisher.