A8723602064077_3 Service Bulletin/Repair Instructions

Technical Service Bulletin

87 Air conditioning refrigerant circuit diagnostic method using calibration gas

87 23 60 2064077/3 October 23, 2023. Supersedes Technical Service Bulletin Group 87 number 23-51 dated

August 18, 2023 for reasons listed below.

Model(s)
© 2023 Audi of America, Inc.
Year
VIN Range
Vehicle-Specific Equipment
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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

A4 allroad, A4,

S4, A5, A5

Cabriolet, A5

Sportback, S5,

S5 Cabriolet, S5

Sportback, A6,

S6 A7, S7, Q3,

A5, SQ5, and

Q7,
2018 – 2024
TT, TTS, and TT

2018 – 2023

Roadster

A3 Cabriolet
2018 - 2019
A3, and S3
2018 – 2020

2022 – 2024
RS 3
2018 – 2020

2024
RS 5
2018 – 2019

2021 - 2024
RS 7
2018

2021 - 2024
A8
2018 – 2021

2024
All
Not Applicable
2018

S8
2020 – 2021

2023

2018
R8, and R8

Spyder
2020 – 2023
TT RS
2018 – 2022
RS 5 Sportback

e-tron quattro

Q8
2019

2021 – 2024

2019

2021 – 2023

2019 – 2024
A6 allroad, e-tron

Sportback

2020 – 2024

quattro, SQ7,

SQ8, and RS Q8

© 2023 Audi of America, Inc.
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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

A8 e quattro
2020 – 2021
Condition

REVISION HISTORY

Revision
Date
Purpose
3
-
Revised Warranty (Add GFF allowance for BEV and PHEV vehicles)
2
8/18/2023
Revised header (Add Model Year 2024)

Revised Service (Add relay and fuse carrier suggestion)

Revised Warranty (Add warranty table)
1
04/15/2022
Initial publication
The cabin air conditioning cooling capacity is insufficient or without function on an R134a or R1234yf refrigerant

system equipped vehicle.
Technical Background

When a refrigerant circuit leak is determined as the root cause of a cabin cooling insufficiency it has traditionally

been diagnosed using either the addition of a contrast dye into the circuit and inspection using ultraviolet light, the

use of an electronic halogen leak detector, or filling the circuit with pressurized nitrogen and searching for the leak

by applying a liquid soap and water solution and inspecting the circuit for the presence of bubble formation. These

methods can be unreliable, particularly, when diagnosing a possible refrigerant leak in the evaporator core.

When diagnosing a possible leak from an evaporator core, false-positive readings from a halogen leak detector

are common and visual access to the evaporator core in an attempt to inspect for the presence of contrast dye or

bubble formation is problematic at the very least.

An additional diagnostic method is now available to analyze a refrigerant leak in the circuit of an R134a or

R1234yf refrigerant system using calibration gas (95% nitrogen / 5% hydrogen) and an electronic hydrogen

detector (VAS523003A). Leak detection using calibration gas has been found to be more effective when

diagnosing a leak source in the areas of the refrigerant circuit that are extremely difficult to access (e.g. the

evaporator core concealed inside the evaporator housing).
Production Solution

Beginning with the R744 refrigerant system in the new Q4 e-tron the leak detection method for this refrigerant

system requires a process that prohibits the use of additives of any kind when diagnosing a leak, creating the

need for a leak detection method using calibration gas. This requires a new tool set. The AT-448 Tool Set Audi

© 2023 Audi of America, Inc.
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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

R744 CO2 A/C Service Introduction (See Service Information circular – Special Tools and Equipment number

ATE-21-21) is now released to all dealers. The tools in this set can be adapted to diagnose R134a and R1234yf

refrigerant circuit leaks as well.
Service

The procedure in this TSB describes a method for leak detection for R134A and R1234yf refrigerant

platforms only. While the diagnostic method for the R744 system in the Q4 e-tron is similar, there are

important differences in the procedure and, as such, should be carried out using the procedure in

ElsaPro.
Extreme caution must be exercised when handling and using calibration gas. The hydrogen component

of the gas mixture is flammable. Failure to employ proper handling and use protocol invites the risk of

serious personal injury or death.
1.
Should the vehicle arrive with insufficient cabin cooling from the air conditioning system recover the

refrigerant remaining in the circuit and compare this amount to the specified volume. A significantly

lesser amount recovered (>50% of total volume lost) indicates an active refrigerant circuit leak.
© 2023 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

2.
Obtain a tank of calibration gas (95%

nitrogen / 5% hydrogen) (Figure 1). This will

need to be sourced locally (e.g. Airgas®).
Figure 1. Calibration gas (95% Nitrogen / 5%

Hydrogen).

3.
The pressure regulator included in the

NITROKITG will not be used as it is only

suitable for connection to a gas tank

containing non-flammable gasses such as

nitrogen (right-hand thread). The AT-448 Tool

Set includes the VAS 584005 pressure

regulator suitable for connection to a gas tank

containing any flammable component as is

the case with the hydrogen component in

calibration gas (left-hand thread). Connect

the VAS 584005 pressure regulator to the

tank (Figure 2). Make sure the tank valve

remains closed.
Figure 2. VAS 584005 pressure regulator attached to

the calibration gas tank.

© 2023 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

4.
Set the HVAC settings to full defrost. Close all of the instrument panel vents and make sure that the

fresh air intake is also closed (recirculation mode). Close off the cabin completely (windows, sunroof,

doors, rear lid, etc.). Then turn off the vehicle completely (key off, no blower activation).
5.
When servicing a high voltage vehicle de-energize the vehicle.
High voltage increases the risk of fatal injury.Severe bodily injury or death by electrocution

or electric arcs is possible.

• Han an Audi high-voltage technician or an Audi high-voltage expert de-energize the highvoltage system.

6.
The NITROKITG includes a service hose and high side service port snap coupler for both an R134a

and R1234yf refrigerant system. This will allow the single connection to the refrigerant circuit of both

an R134a as well as an R1234yf equipped vehicle. Use the snap coupler appropriate for the

refrigerant platform being serviced from the NITROKITG to complete the connection.
7.
Evacuate the vehicle refrigerant circuit for 15

minutes. After the refrigerant circuit is free of

any refrigerant connect the service manifold

from the NITROKITG Automotive A/C

Nitrogen Leak Test Kit to the high side

service port. Use the appropriate snap

coupler for the platform of the circuit being

serviced. (Figure 3).
Figure 3. NITROKITG manifold connected to the high

side service port.
© 2023 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

8.
Only one of the ports needs to be connected

for this diagnosis. The connection to the high

side port is shown in Figure 4.
Figure 4. NITROKITG high side snap coupler

connected to the high side service port.

9.
Connect the VAS 584005 Pressure Reducer

to the NITROKITG manifold. Fill the circuit

with calibration gas to an absolute pressure

of no greater than 14 bar (Figure 5).
Figure 5. Calibration gas pressure in the circuit.
The air conditioning system must not be activated while the circuit is charged with calibration

gas. Running the air conditioning system while it is charged with calibration gas will damage the

compressor.If necessary apply a warning sign to the vehicle stating “Do Not Run” or a similar
© 2023 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

warning to prevent accidental operation while the circuit is filled with calibration gas for the

purposes of diagnosis.

10. After the circuit is charged allow the circuit pressure to equalize for 20 minutes. Leak detection can

then begin.

11. Close off the defroster outlets with masking

tape leaving a small opening for the VAS

523003A gas leak detector probe (Figure 6).
Figure 6. VAS 523003A gas leak detector in place in

the defroster outlet.
© 2023 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

12. The gas leak detector VAS 523003A reacts

to the hydrogen component in the calibration

gas. Since hydrogen is lighter than air, it will

rise to the position of the detector probe. The

hydrogen content in the calibration gas,

however, evaporates after a short period of

time (Figure 7).

Perform the leak diagnosis immediately after

charging the refrigerant circuit with calibration

gas and the 20-minute equalization period.

Depending on the conditions, it may be

necessary to recharge the refrigerant circuit

with calibration gas in an attempt to clearly

identify a circuit leak at the evaporator core.
Figure 7. VAS 523003A in place in the defroster

outlet and hydrogen presence is detected.

13. If no leak is detected through the defroster outlet using this method the evaporator core is not the

source of the refrigerant leak and the evaporator core is not to be replaced. Continue diagnosis using

the VAS 523003A along all remaining components of the refrigerant circuit to determine the source of

the leak.

14. When any and all leak sources have been identified close the valve on the top of the calibration gas

tank. Any calibration gas that remains in the refrigerant circuit can be slowly ventilated until the

circuit pressure has equalized with atmospheric pressure. Proceed with the necessary repairs,

evacuate the refrigerant circuit, and recharge the system as necessary.

15.

Should the evaporator for the Q5 be

confirmed leaking by way of this

diagnostic procedure and replacement

of the evaporator is performed it is

necessary to loosen and refasten the

Relay and Fuse Carrier 3 -SR3- (shown

in figure 8, position 1) in the course of

the repair. During reassembly of the

vehicle it is critically important that this

relay and fuse carrier in particular be

reinstalled in its correct original

© 2023 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

position. Failure to reinstall the Relay

and Fuse Carrier 3 precisely will result in

water intrusion and subsequent

component damage.
Figure 8. Relay and fuse carrier 3 -SR3-.
16. When re-energizing a high voltage vehicle observe the following:
High voltage increases the risk of fatal injury.Severe bodily injury or death by electrocution

or electric arcs is possible.

• Have an Audi high-voltage technician or an Audi high-voltage expert to bring the highvoltage system back into service.
Warranty

Claim Type:
• 110 Up to 48 Months/50,000 Miles.

• G10 for CPO Covered Vehicles – Verify Owner.

• If the vehicle is outside of any warranty, this Technical Service Bulletin is

informational only.
Service Number:
8760
Damage Code:
0050
Labor Operations:
Evaporator remove and reinstall
8760 1950
See SRT with

associated operations
8515 1950
See SRT with

associated operations
Air conditioner check
8760 0199
Time necessary for

diagnosis supported

by punch time (Max

130 TU)
GFF (BEV and PHEV vehicles only. No

GFF allowance for non BEV and PHEV

vehicles)
0150 0000
Time stated on the

diagnostic protocol

(Max 50 TU)
Road test prior to the service procedure
No allowance
0 TU
Road test after the service procedure
No allowance
0 TU
(All models except e-tron GT)

Heating, ventilation unit remove and

reinstall

(e-tron GT)
Diagnostic Time:
© 2023 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

As per TSB 2064077/3

Claim Comment:

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

Tool Number
Tool Description
VAS581009
R744 CO2 A/C Service Unit

VAS584005
Pressure Reducer and Hose

NITROKITG
Automotive A/C Nitrogen Leak Test Kit
© 2023 Audi of America, Inc.
Page 11 of 12
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

VAS523003A
Gas Leak Detector
Additional Information

All part and service references provided in this TSB (2064077) are subject to change and/or removal. Always

check with your Parts Department and/or ETKA for the latest information and parts bulletins. Please check the

Repair Manual for fasteners, bolts, nuts, and screws that require replacement during the repair.

©2023 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.
© 2023 Audi of America, Inc.
Page 12 of 12
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.

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