NHTSA ID Number: 11017344
Manufacturer Communication Number: 25-01-019G-1 TSB
TSB/Document Date: 2025-04-30
Summary
Certain G80 (RG3) and G90 (RS4) vehicles equipped with the 2.5T-GDI Theta III or 3.5T-GDI Lambda III engine may exhibit reduced air conditioning performance due to chemical damage to the suction and discharge seal washers caused by foreign substances. This bulletin provides instructions to replace the A/C suction and discharge seal washers to resolve the concern.
Place the measured amount during recovery
back into the vehicle; approx. 3~10 mL.
i
•
•
Information
Refrigerant Type: R-1234YF
Refrigerant Capacity:
• 630 ±25 g or 1.38 ±0.05 lbs
13.
Start the vehicle and verify A/C operation.
14.
Reprogram the radio with the guest’s presets.
15.
The service procedure is now complete.
1.
Record the guest’s radio presets and then
disconnect the negative battery (−) terminal.
2.
Remove LH strut bar (A).
3.
Disconnect the dual purge connectors (B) and
dual purge hoses (C) on the air cleaner
assembly.
A
C
B
TSB #: 25-01-019G-1
Page 8 of 16
4.
Refer to the shop manual to connect the
refrigerant recovery/recycling equipment to the
high-pressure service port (D) and lowpressure service port (E) and recover the
refrigerant.
i
•
•
E
D
Information
Be sure to drain or measure the
amount of oil in the reservoir prior to
recovery to accurately determine how
much oil was drained.
Heating, Ventilation and Air
Conditioning > Air Conditioning System
> Refrigerant Recovery / Recycling /
Charging / Vacuum / Leak Test >
o Install the Refrigerant Recovery /
Recycling / Charging Equipment
o Refrigerant Recovery Operation
i
Information
• Refrigerant Type: R-1234YF
• G80 (RG3) 3.5T
Refrigerant Capacity:
630 ±25 g or 1.38 ±0.05 lbs
• G90 (RS4) 3.5T
Refrigerant Capacity:
700 ±25 g or 1.54 ±0.05 lbs
TSB #: 25-01-019G-1
Page 9 of 16
5.
Measure the amount of PAG oil drained during
recovery and record it so that amount can be
injected later during the recharging process.
6.
Remove the engine covers (F) and
engine room cover (G).
F
F
F
G
TSB #: 25-01-019G-1
Page 10 of 16
7.
Disconnect the ECM connector (H) and place
it in the direction of the white arrow as shown.
H
8.
Remove the air cleaner assembly (I).
Tightening Torque:
I
9.
lb-ft
17
N.m
12
Remove the two fixing bolts (J) and remove
the air duct (K).
J
K
J
TSB #: 25-01-019G-1
Page 11 of 16
10.
Remove the mounting nut (L) and disconnect
the discharge line (M).
NOTICE
Do NOT remove the suction line
mounting nut directly next to the
discharge line.
L
Tightening Torque:
11.
lb-ft
17
N.m
12
M
Remove the suction line mounting nut (N) and
disconnect the suction line.
Tightening Torque:
12.
lb-ft
17
N.m
12
N
Remove the suction and discharge line
O-rings.
i
Information
Do NOT re-use the green suction and
discharge line O-rings.
Keep the O-rings for the Digital
Documentation photo.
TSB #: 25-01-019G-1
Page 12 of 16
13.
Disconnect the intercooler hose (O) from the
quick connector clamp by pulling the sides (P)
and top (Q). Remove the intercooler hose.
O
Q
O
P
P
14.
Loosen the fixing clamp and remove the air
intake hose (R).
Tightening Torque:
lb-ft
17
N.m
12
R
TSB #: 25-01-019G-1
Page 13 of 16
15.
Remove the mounting bolt (S) then disconnect
the discharge hose (T).
Remove the suction hose bolt (U) and suction
hose (V).
S
Tightening Torque:
lb-ft
17
N.m
12
S
U
V
T
16.
Remove the suction hose seal washer (W).
i
Information
Keep the washers for the Digital
Documentation photo.
W
TSB #: 25-01-019G-1
Page 14 of 16
17.
Remove the discharge hose seal washer (X).
i
Information
Keep the washers for the Digital
Documentation photo.
18.
X
DIGITAL
DOCUMENTATION
Using STUI, take a photo of the OLD
discharge and suction seals and
O-rings removed next to the NEW
discharge and suction seals and
O-rings in the bag with the last 6 digits
of the VIN and the date of repair on a
piece of paper.
Upload the photo to STUI.
19.
Install the new seal washers onto the suction
hose and discharge hose.
Install the new O-rings onto the suction line
and discharge line.
i
Information
Clean both sides of the mating surface
prior to installation to remove any residual
debris left by the discharge and suction
seal washers.
TSB #: 25-01-019G-1
Page 15 of 16
20.
Reinstall the discharge hose (Y) onto the
compressor assembly, then the suction hose
(Z).
Y
Tightening Torque:
lb-ft
17
Z
N.m
12
21.
Refer to the shop manual to vacuum and
recharge the A/C system:
• Heating, Ventilation and Air
Conditioning > Air Conditioning System
> Refrigerant Recovery/Recycling/
Charging/Vacuum/Leak Test >
o Refrigerant System Vacuum
Operation
o Refrigerant Charge
22.
Use the R-1234YF PAG Oil Syringe Injection
tool and add PAG Oil with UV Dye.
Place the measured amount during recovery
back into the vehicle; approx. 3~10 mL.
i
Information
• Refrigerant Type: R-1234YF
• G80 (RG3) 3.5T
Refrigerant Capacity:
630 ±25 g or 1.38 ±0.05 lbs
• G90 (RS4) 3.5T
Refrigerant Capacity:
700 ±25 g or 1.54 ±0.05 lbs
23.
Once the recharge process has completed,
re-install all removed parts in the reverse
order.
24.
Start the vehicle and verify A/C operation.
25.
26.
Reprogram the radio with the guest’s presets.
The service procedure is now complete.
TSB #: 25-01-019G-1
Page 16 of 16
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TSB/Document ID: 25-01-019G-1 TSB
Replacement Service Bulletin Number:
MFR Communication Date: 2025-04-24
MFR Internal Campaign ID/Software Version: 911G
Communication Type: Service Campaign
NHTSA Components: UNKNOWN OR OTHER
MFR Component System:
MFR Component Subsystem:
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