A872474202012414

Technical Service Bulletin
87 Air conditioning inoperative; DTC 00457, 00256, 01592
87 24 74 2020124/14 April 29, 2024. Supersedes Technical Service Bulletin Group 87 number 15-69 dated
August 24, 2015 for reasons listed below.
Model(s)
Year
A6
2007 - 2014
A6 Avant
2007 - 2011
VIN Range
Vehicle-Specific Equipment
All
Not Applicable
2007 - 2011
S6
2013 - 2014
A5, and S5
2008 - 2014
2008 - 2013
R8
2014
A4, A4 Avant,
and Q5
2009 - 2014
S4, A5 cabriolet,
S5 Cabriolet
2010 - 2014
A8
2011 - 2014
R8 Spyder
2011 - 2012
2014
R8 GT, and R8
GT Spyder
2012
A7
2012 - 2014
RS 5, RS 5
Cabriolet, S7, Q5 2013 - 2014
Hybrid, and SQ5
Condition
REVISION HISTORY
Revision
Date
Purpose
14
-
Revised header (Corrected model codes and model years).
Revised Warranty (Changed damage code, corrected labor operations)
Revised Required Parts and Tools (Update sensor part number)
13
08/24/2015
© 2024 Audi of America, Inc.
Internal
Revised Required Parts and Tools (Added sensor seal)
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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
12
4/25/2014
Revised Warranty (Changed damage code, corrected labor operations)
• 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.
Service
For A4/S4 (8K), A5/S5 Coupe/Cabriolet (8T/8F), Q5, A6, A7, 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.
© 2024 Audi of America, Inc.
Internal
Page 2 of 8
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
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
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).
© 2024 Audi of America, Inc.
Internal
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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
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.
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.
© 2024 Audi of America, Inc.
Internal
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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
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 A-pillar 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.
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.
© 2024 Audi of America, Inc.
Internal
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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
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.
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.
© 2024 Audi of America, Inc.
Internal
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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
Warranty
Claim Type:
• 110 Up to 48 Months/50,000 Miles.
• G10 for CPO Covered Vehicles – Verify Owner.
• If vehicle is outside of any warranty, this Technical Service Bulletin is
informational only.
Service Number:
8757 – Pressure sensor inspection / replacement or refrigerant circuit repairs
9715 – Electrical wiring inspection and repairs
Damage Code:
0040 - Pressure sensor inspection / replacement or refrigerant circuit repairs
0033 - Electrical wiring inspection and repairs
Labor Operations:
Diagnostic Time:
Check front left wiring loom
9709 0199
175 TU
Repair front left wiring loom
9709 4199
165 TU
Drain and refill refrigerant (if necessary)
8703 1700
See SRT with
associated
operations
Replace A/C pressure/temperature sensor
(G395)
8709 XXXX
See SRT with
associated
operations
GFF
0150 0000
(See Elsa)
Time stated on
the diagnostic
protocol
(Max 50 TU)
Claim Comment:
Road test prior to service procedure
No allowance
0 TU
Road test after service procedure
No allowance
0 TU
As per TSB 2020124/14
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
4H0959126C
Pressure sensor
1
7H0820896
O-ring
1
© 2024 Audi of America, Inc.
Internal
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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
Additional Information
All parts and service references provided in this TSB (2020124) are subject to change and/or removal.
©2024 Audi of America, Inc. All rights reserved. The 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.
© 2024 Audi of America, Inc.
Internal
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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.