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Technical Service Bulletin

93 Charging door does not open when button pressed - B1A8FFO, B1A89F0, B1A8AF3, B1A88F3

United States 444 Volkswagen of America, Inc. (6444)

[Status _[Released for publishing

New customer code

Object of complaint Complaint type
body attachments and installations -> doors, lids operation -> open fuel filler door functionality -> cannot be opened [|
body attachments and installations -> doors, lids operation > open high-voltage charging port | tionality -> no function ||
body attachments and installations -> lids functionality [|
power vehicle electrical system, data transfer > power supply -> high-voltage battery charging | nctionalty -> cannot be released ||
power, vehicle electrical system, data transfer > battery management > charging high-voltage | ssctionaity -> no function ||
power, vehicle electrical system, data transfer > battery management -> charging high-voltage _|functionality -> operation sequence

battery incorrect

power, vehicle electrical system, data transfer -> power supply -> high-voltage battery charging [component, automotive fluids ->

socket cap damaged

body attachments and installations -> doors, lids operation -> close high-voltage charging port | .ctignalty -> no function ||
body attachments and installations -> doors, lids operation -> close fuel filler flap functionality -> cannot be closed [|
New workshop code

Object of complaint Complaint type [Position]

body attachments and installations -> lids -> charging port door|component, automotive fluids -> damaged] __—|

Vehicle data

e-tron

Sales types

aoa PT

aaa [of

Chassis numbers

[Manufacturr[Fiter|ype[ Fier] Factory [From [To [Pred fom [Prod to

lat > Joe [Fe [5 Jooooofoooaao_ |_|

Documents

A Connection offline
Technical Service Bulletin Transaction No.: 2071343/2
93 Charging door does not open when button pressed - B1A8FFO, B1A89F0, B1A8AF3, B1A88F3 Release date: Mar 31, 2025
Condition
REVISION HISTORY
revision ono lpupore
| 09/13/2023 | Initial publication
Customer states:
The charging door does not open when the button is pressed.
Workshop findings:
+ Left and right or only left/right charging door can no longer be opened by pressing the button
+ Itcan only be opened using the manual release mechanism
One or more of the following DTCs are stored in the -J1050- High Voltage Battery Charger (address word 00C6):
+ B1A8FFO: LED module charging socket door 1 communication maifunction.
+ B1A89F0: LED module charging socket door 2 communication malfunction.
+ B1A8AF3: Charge door 1 LIN actuator communication malfunction
+ B1A88F3: Charge door 2 LIN actuator communication malfunction
Technical Background
Quality issues in the production process may lead to a crack in the connector point of the charging indicator (Figure 1). Moisture can reach the contact
pins in the charging indicator connector via this crack. As a result, a bypass can occur between the ground contact pin and the LIN contact pin. This
leads to a communication fault between the components of the charging door and the charging unit for high-voltage battery. In this circumstance, the
electric operation of the charging door does not work.
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Figure 1: Crack in the connector point of the charging indicator. Figure 2: Evidence of water intrusion in the charging indicator connector.
Figure 3: Evidence of water intrusion in the connector housing.

Production Solution
After July 2020, the charging indicator connector and the connector housing are sealed during production to prevent moisture ingress.
Service
Try to reproduce the customer complaint (based on the description/cause of the issue) so that it can be clearly assigned to this TSB. The
following repair must only be carried out if all of the criteria (model/type, chassis number, engine/motor code, gearbox code, PR number(s),
part number, software version, code, etc.) apply exactly. Otherwise, this solution will not eliminate the problem and repeat repairs may be
necessary. In such a case, claims for replaced parts will be subject to review.
Please take photos of the complaint and upload them into DOC-IT with the repair order. Photos should:
+ Have a date stamp and VIN reference.
+ Be taken in focus and with sufficient light.
Measure:
For vehicles with one charging door (driver side): Remove wheel and wheel housing liner.
For vehicles with two charging doors: Remove both wheels and wheel housing liners.
Follow the instructions in Elsa to complete the repair at Repair Manual >> General body repairs, exterior >> Rep. gr. 66 Exterior equipment >> Wheel
housing liners >> Assembly overview - wheel housing liner (front).
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 de-energize the high-voltage system.
1. Unplug the connector from the charging indicator (Figure 4). er:
Check the contacts and connector of the charging indicator(s). a
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Figure 4: The connector has been unplugged.
2. Check the contacts on the connector housing and on the
charging indicator for oxidation. 7
Figure 5: Oxidation on the connector housing.

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Figure 6: Use inspection mirror to carefully examine the charging indicator
connector.
3. Check the connector point on the charging indicator for cracks y ii ch 7,
(Figure 1). 4, ‘ae eA
If the connector point is cracked or the pins are oxidized (Figure r =
7), replace the damaged charging door unit as described under J =
the heading “Removing and installing charging door unit” a |
below, & ;
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Figure 7: Oxidation of the pins on the charging indicator connector.
4. To avoid the need for repeat repairs, check whether the charging door supplied by the parts department already has a sealed charging indicator
connector. This can be identified on the basis of the QR code sticker and the red line on the connector (Figure 8)
If this is not the case, seal the charging indicator connector on the new charging door unit with 1-component adhesive sealant (Part number D
469101A3) as described under the heading “Sealing charging indicator connector”.
This can be performed both when the component has been removed, and when itis fitted in the vehicle.
If the connector point, and contacts of the charging indicator on one of the charging doors are undamaged, the charging door can remain in the
vehicle.
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Figure 8: The charging indicator connector pictured is the updated part.
5. After replacing the damaged charging door unit, check that the charging doors open and close when the button is pressed.
Ifa charging door unit can remain in the vehicle, the charging indicator connector on it must also be sealed with 1-component adhesive sealant
(part number D 4691013) as described under the header “Sealing charging indicator connector”.
Removing and installing the charging door unit:

7. Unplug the electrical connector inside of the wheel well (1), al
release the catch (3), remove the bulb (2), and unplug the a
electrical connector in the back of the bulb (4) (Figure 14). s
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Figure 14: Overview of the position of the charging door (installed).
© NOTICE
The wheel arch extension must be pressed away carefully at the same time to enable the charging door to be removed.
8. Use hook 3438 (Figure 15) or a screwdriver to release the
remaining catches (1, 2, 3, and 4) (Figure 16). 3438
Carefully take the charging door unit out of the wing. -*
Figure 15: Hook 3438.

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Figure 16: Charge door retaining tabs.
9. Follow the instructions in Elsa to remove the trim for the = 4 .
charging door unit and install a new unit at Repair Manual >> fit &
Body >> Body Exterior >> 55 Hoods Lids >> Charge Door y A \
Unit >> Charge Door Unit Trim, Removing and Installing. - ts 4 \ \ ]
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Figure 17: Charge door exterior cover.
Installing the charging door unit (without removing the driver door and wheel arch extension):
© notice
To avoid paintwork damage, mask off the area around the charging door in advance using adhesive tape (Figure 18). The adhesive tape
can be removed when the charging door has been installed.

1. Unplug the Baca
connector from the e
charging indicator
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Figure 20: The connector is unplugged from the charging indicator.
2. Screw the i aa
application hose : = ie ad — oe
(2) (order number: fe a ae.
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onto the cartridge Me areas
of the component me aie eis
adhesive sealant ee ae
(1) (Part number D . ogi
469101A3) (Figure ——— a € od
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Figure 21: Component adhesive sealant and tool.
The application hose (order number: ASE33522600000) can be left on the cartridge of the component adhesive sealant (part number: D 469101A3)
after use and can be reused as the adhesive sealant (butyl) does not harden.

3. Inorder to ensure that the adhesive a: we
sealant has the same consistency at each pit
use after it has not been used for a longer BB
period (several days) use cartridge (3, 1:8 ARNG
Figure 21) to press out a sealant bead cure oe
with a length of approximately 5 cm Soe
(Figure 22) before each use of the eee eg
component adhesive sealant. Beas
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Figure 22: Clearing the component adhesive sealant after prolonged storage.
4. Apply a sealant bead (at least 8 mm . el
thick) all around at the beginning of the :
connector point of the charging indicator a
(Figure 23). | a
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Figure 23: Sealant bead applied at the connector.

5. Plug the connector into the charging B ae
indicator and press it into the adhesive =
sealant. Press in the release tab on the = \m@ - a a
connector to ensure it is fully engaged *) s 4
Plug the connector into the charging fz = é
indicator The connector should then be f. > N
completely surrounded by the adhesive = Be ee = >

lant (Figure 24). Q wn (are
sealant (Figure 24). | . We ee \
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Figure 24: The connector should be completely surrounded by the adhesive sealant.
The entire connector and connector point of the charging indicator and parts of the charging indicator must be covered with adhesive
sealant to ensure protection against moisture ingress (Figure 25).
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Figure 25: The entire connector and the connector point of the charging indicator must be covered with adhesive sealant.

The adhesive sealant is very soft and flows into itself immediately after application.

— Some of the adhesive sealant may run off shortly after application. This does not affect the sealing function; instead, it is a sign that
sufficient adhesive sealant has been applied.

— The adhesive sealant hardens and reaches its final elastic consistency over time.

— The vehicle can then be reassembled and returned to the customer.

— No waiting time is necessary as the initial strength of the adhesive sealant can withstand everyday use.

Warranty
Claim Type: + If the vehicle is outside of any warranty, this Technical Service Bulletin is informational only.
Damage Code: 0033
Labor Operations: Seal charging indicator 9355 5199 60 TU
Seal 2 charging indicators 9355 5299 100 TU
Replace charging door unit 9353 5599 90 TU
Replace 2 charging door units 9353 5699 140 TU
Seal charging indicator (one side) and replace charging door | 9355 5699 130 TU
unit (other side)
GFF 0150 0000 Time stated on the diagnostic
protocol
Charge Battery 2706 8950 See SRT with associated
operations
Claim Comment: As per TSB 2071343/2
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
Always check with your Parts Department and/or ETKA for the latest information and parts bulletins.
[pannumber |pantoescipion enti |
4KE810001 Charging door
4KE810002 Charging door 2
4KE8536013Q7 _| Lettering
D469101A3 Adhesive sealant
ASE33522600000 | Application hose Shop Supply
Tool Number | Tool Description
Additional Information
All parts and service references provided in this TSB (2071343) are subject to change and/or removal
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