NHTSA ID Number: 10244532
Manufacturer Communication Number: A8723602064077_3
TSB/Document Date: 2023-11-06
Summary
This TSB describes a method for leak detection for R134A and R1234yf refrigerant platforms only.
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
Page 1 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
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.
Page 2 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
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.
Page 3 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
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.
Page 4 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
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.
Page 5 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
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.
Page 6 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
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.
Page 7 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
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.
Page 8 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
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.
Page 9 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
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.
Page 10 of 12
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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
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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TSB/Document ID: A8723602064077_3
Replacement Service Bulletin Number:
MFR Communication Date: 2023-10-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:REFRIGERANT HOSES AND FITTINGS
MFR Component System:
MFR Component Subsystem:
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